av80xop tandem roller

AV 80 X4

Operating manual

Articulated tandem roller

AV 80 X4

Cummins Tier 2

09/2008

Operating manual

Edition EN

Articulated tandem roller

1AV 80 X4

400100

Congratulations on your purchase of an AMMANN road roller. This modern compaction device is characterised by simple operation and maintenance and is the product of many years of AMMANN experience in the field of road roller engineering. In order to avoid faults due to improper operation and maintenance we request that you read this operating manual with great care and keep it for later reference.

With kind regards,

Ammann Czech Republic a.s. | Náchodská 145 | CZ–549 01 Nové Město nad Metují

% + 420 491 476 111 | Fax + 420 491 470 215 | [email protected] | www.ammann-group.cz

This manual consists of:

I. Specification manual II. Operating instructions III. Maintenance manual

The following explanations serve to familiarise the machinist (operator) with the roller and to support him during handling and maintenance. It is therefore absolutely necessary to provide the operator with these instructions and to ensure that he reads them carefully before using the road roller. This aids training compre-hension during the first use of the road roller.

Subsequent faults due to improper operating are avoided.

Adherence to maintenance instructions increases the reliability and lifetime of the machinery. It reduces re-pair costs and down time.

AMMANN accepts no liability for continued safe functioning of the road roller if it is incorrectly operated and / or operating modes are employed which represent improper use.

Spare parts must meet AMMANN technical specifications. These requirements are fulfilled if only original AM-MANN spare parts are used.

These instructions must always be kept available on the equipment.

2 AV 80 X4

Preface

Information, specifications, and recommended operation and maintenance instructions contained in this publication are basic and final information at the time of the printing of this publication. Printer’s errors, tech-nical modifications, and modifications of figures are reserved. All dimensions and weights are approximate and, therefore, not binding.

Ammann Czech Republic a.s. reserves the right to perform modifications without obligation to inform the machine user. If you identify any differences between the machine operated by you and the information con-tained in this publication, contact your local dealer.

Reproduction or copying of any kind is prohibited without the written permission of Ammann Czech Republic a.s.

3AV 80 X4

! WARNING !

As used in this operating manual, the terms „right“, „left“, „front“ and „rear“ indicate the sides of the machine moving forward.

SYMBOLS OF THE SAFETY NOTICES IN THE OPERATION MANUAL:

The notice warns of a serious risk of personal injury or other personal hazards.

The notice warns of possible damages to the machine or its parts.

The notice warns of the necessity of environmental protection.

FRONT

REAR

RIGHTLEFT

400101en

4 AV 80 X4

Content

Content .............................................................................................................................................................4

1. SPECIFICATION MANUAL ......................................................................................................................9

1.1. Basic specification ................................................................................................................................10

1.1.1. Area of use ................................................................................................................................................................................................................10

1.1.2. Machine design ......................................................................................................................................................................................................10

1.2. Machine dimension scheme ................................................................................................................12

1.3. Technical data .......................................................................................................................................14

1.3.1. Weights ......................................................................................................................................................................................................................14

1.3.2. Drive of travel - driving properties ..................................................................................................................................................................14

1.3.3. The vibrations ..........................................................................................................................................................................................................14

1.3.4. Engine ........................................................................................................................................................................................................................14

1.3.5. Brakes .........................................................................................................................................................................................................................15

1.3.6. Drive ...........................................................................................................................................................................................................................15

1.3.7. Fills ...............................................................................................................................................................................................................................15

1.3.8. Sprinkling ..................................................................................................................................................................................................................15

1.3.9. Electrical installation .............................................................................................................................................................................................15

1.3.10. Hygienic parameters .............................................................................................................................................................................................16

5AV 80 X4

OPERATING MANUAL

2. OPERATION MANUAL ..........................................................................................................................19

2.1. Major Safety Precautions .....................................................................................................................21

2.1.1. Safety Measures during Machine Operation ..............................................................................................................................................21

2.1.1.1. Compaction Work Commencement ..............................................................................................................................................................21

2.1.1.2. Work Safety Secured by User .............................................................................................................................................................................21

2.1.1.3 Ensurance of safety measures by the owner ...............................................................................................................................................22

2.1.1.4. ROPS Cab .................................................................................................................................................................................................................22

2.1.2. Reguirements on Driver’s Qualification .........................................................................................................................................................23

2.1.3. Driver’s Liabilities ...................................................................................................................................................................................................23

2.1.4. Banned Operations ...............................................................................................................................................................................................25

2.1.5. Safety inscriptions and signs used on the Machine .................................................................................................................................26

2.1.6. Hand Signals ............................................................................................................................................................................................................30

2.2. Ecological & Hygienic Principles .........................................................................................................33

2.2.1. Hygienic Principles ...............................................................................................................................................................................................33

2.2.2. Ecological Principles ............................................................................................................................................................................................33

2.3. Preservation & Storage .......................................................................................................................34

2.3.1. Short-Term Preservation & Storate for the Period of 1 ÷ 2 Months .....................................................................................................34

2.3.2. Machine Preservation & Storage for the Period Over 2 Months Long ................................................................................................34

2.3.3. De-conservation and inspection of brand new machines .....................................................................................................................35

2.4. Machine Disposal Following Its Life Termination ..............................................................................36

2.5. Machine Description ............................................................................................................................37

2.6. Controls & Dashboard Instruments ....................................................................................................38

2.7. Machine basic functions control .........................................................................................................58

2.7.1. Engine starting .......................................................................................................................................................................................................59

2.7.2. Machine travel and reversing with no vibration .........................................................................................................................................63

2.7.3. Machine travel and reversation incl. vibrations ..........................................................................................................................................69

2.7.4. Driving with vibrations on compacted and hard materials....................................................................................................................69

2.7.5. Compacting near constructed facilities .........................................................................................................................................................69

2.7.6. How to stop the Machine and its engine ......................................................................................................................................................71

2.7.7. Safe stopping of the Machine ...........................................................................................................................................................................71

2.7.8. Emergency stop of the Machine ......................................................................................................................................................................73

2.7.9. Machine shutdown ...............................................................................................................................................................................................73

2.7.10. Sprinkling ..................................................................................................................................................................................................................73

2.7.11. How to lift and let down the engine bonnet ...............................................................................................................................................74

2.8. Machine transport ................................................................................................................................75

2.8.1. Machine towing......................................................................................................................................................................................................75

2.8.2. How to load the Machine ....................................................................................................................................................................................77

2.8.3. Transporting by the road ....................................................................................................................................................................................78

2.9. Special conditions to use the Machine ...............................................................................................79

2.9.1. How to operate the Machine during its running-in ..................................................................................................................................79

2.9.2. Operating the Machine at low temperatures ..............................................................................................................................................79

2.9.3. Machine operation at high temperatures and humidity .........................................................................................................................79

2.9.4. Machine operation at high altitudes ..............................................................................................................................................................79

2.9.5. Machine operation within very dusty environment .................................................................................................................................79

6 AV 80 X4

Content

3. MAINTENANCE MANUAL ....................................................................................................................83

3.1. Safety and other measures for machine maintenance ......................................................................85

3.1.1. Safety of machine maintenance .......................................................................................................................................................................85

3.1.2. Fire precautions during operation media exchanges...............................................................................................................................85

3.1.3. Ecological and hygienic principles ..................................................................................................................................................................86

3.2. Media specification ..............................................................................................................................87

3.2.1. Engine oil ................................................................................................................................................................................................................87

3.2.2. Fuel .............................................................................................................................................................................................................................88

3.2.3. Hydraulic oil ............................................................................................................................................................................................................88

3.2.4. Lube grease .............................................................................................................................................................................................................89

3.2.5. Coolant ......................................................................................................................................................................................................................89

3.2.6. Glass washer fluid .................................................................................................................................................................................................90

3.3. Media ....................................................................................................................................................91

3.4. Lubrication and Maintenance Chart ...................................................................................................92

3.5. Lubrication Chart ..................................................................................................................................94

3.6. Lubrication and Maintenance Operations ..........................................................................................95

Following the 20 hours of operation or daily .....................................................................................96

3.6.1. Inspect, refill the oil amount in the engine ..................................................................................................................................................96

3.6.2. Inspect, replenish the engine coolant amount ...........................................................................................................................................97

3.6.3. Inspect the engine belt .......................................................................................................................................................................................98

3.6.4. Crankcase breather ...............................................................................................................................................................................................98

3.6.5. Inspect air filter vacuum valve ..........................................................................................................................................................................99

3.6.6. Inspect fan condition ...........................................................................................................................................................................................99

3.6.7. Check fuel amount ............................................................................................................................................................................................. 100

3.6.8. Inspect oil amount in the hydraulic circuit tank ..................................................................................................................................... 101

3.6.9. Fill up sprinkling water tank ........................................................................................................................................................................... 101

3.6.10. Inspect alarm and control devices ................................................................................................................................................................ 102

Following 250 hours of operation (after 3 months) .........................................................................104

3.6.11. How to exchange motor oil and oil filter .................................................................................................................................................... 104

3.6.12. Inspect engine induction manifold .............................................................................................................................................................. 106

3.6.13. Inspect engine cooling circuit ........................................................................................................................................................................ 107

3.6.14. Inspect the battery ............................................................................................................................................................................................. 108

3.6.15. Inspect the function of air filter vacuum switch ...................................................................................................................................... 110

3.6.16. Sprinkling filter & sprinkler strainer.............................................................................................................................................................. 111

3.6.17. Machine lubrication ........................................................................................................................................................................................... 112

3.6.18. How to replace fuel filter ................................................................................................................................................................................. 114

3.6.19. Inspect coolant concentration ...................................................................................................................................................................... 114

Following 1000 hours of operation (after 1 year) ............................................................................115

3.6.20. Inspect engine belt ............................................................................................................................................................................................ 115

3.6.21. Inspect the exhaust system ............................................................................................................................................................................. 115

3.6.22. Inspect the silencing system .......................................................................................................................................................................... 116

3.6.23. Clean the water tank .......................................................................................................................................................................................... 117

7AV 80 X4

OPERATING MANUAL

Following 2000 hours of operation (every 2 years) .........................................................................118

3.6.24. Inspect, adjust engine valve clearance ....................................................................................................................................................... 118

3.6.25. Engine coolant exchange ................................................................................................................................................................................ 121

3.6.26. How to exchange oil in the vibrators and bearings of the drums. .................................................................................................... 124

3.6.27. How to exchange hydraulic oil and filters.................................................................................................................................................. 125

Maintenance as required ...................................................................................................................129

3.6.28. Fuel system breathing ....................................................................................................................................................................................... 129

3.6.29. How to replace air filter elements ................................................................................................................................................................. 130

3.5.30. How to clean water separator of fuel filter ................................................................................................................................................ 132

3.6.31. Clean the engine radiators and hydraulic oil coolers ............................................................................................................................ 133

3.6.32. How to clean cab ventilation filter ................................................................................................................................................................ 133

3.6.33. Drain water from sprinkling circuit before winter season .................................................................................................................... 134

3.6.34. Adjust the scrapers ............................................................................................................................................................................................. 136

3.6.35. Machine cleaning ............................................................................................................................................................................................... 137

3.6.36. Check the tightening of bolted connections ............................................................................................................................................ 137

3.7. Defects .................................................................................................................................................140

3.8. Attachments ........................................................................................................................................142

AV 80 X4 Wiring Diagram .................................................................................................................................................................................................. 142

AV 80 X4 Hydraulic Diagram ........................................................................................................................................................................................... 146

8 AV 80 X4

9AV 80 X4

1. SPECIFICATION MANUAL

AV 80 X4(Cummins tier 2)

10 AV 80 X4

1.1.1. Area of use

The machines of these series are engineered for operations un-der the conditions due to the CSN IEC 721-2-1 (038900) : WT, WDr, MWDr (i.e. temper climate zone, hot dry zone or warm dry zone with limited temperature scope from –7 °C (19,4 °F) to +45 °C (113 °F) of ambient temperature.)

1.1.2. Machine design

The tandem vibration roller AV 80 X4 with an articulated frame enables the steering and offset of drums (crabbing). The roller conception allows compaction close to curbs or walls. The cabin is in version with integrated frame ROPS, compliant with inter-national standards ISO 3471:1994/Amd.1:1997; EN 13510:2000; SAE J/ISO 3471:2003; AS 2294-2003; for maximum machine weight 9000 kg (19845 lb).

The rollers can be used for compaction of asphalt composi-tions to the layer thickness (after compaction) of 140 mm (5,5 in), hydraulic cemented compositions to the layer thickness of 200 mm (7,9 in), composed earth to the layer thickness of 270 mm (10,6 in), sand and gravel materials to the layer thick-ness of 370 mm (14,6 in).

The rollers are not convenient for compaction of rockfill, alumi-nous and clayey materials.

The machine meets requirements of international standards for hygiene, ergonomics and safety of operation and is provided with the production plate CE.

Machine’s production label – CE

The machine does not comply with the conditions for being marked with the “CE” symbol and it is equipped with a name plat without “CE“.

Please fill in the following data:

(see Pin label, Label of the CUMMINS engine)

Type of machine

................................................................................................................

ICV/PIN (Serial number of the machine)

................................................................................................................

Production year

................................................................................................................

Type of engine

................................................................................................................

Serial number of the engine

................................................................................................................

The data mentioned in the table refer always when you contact the dealer or manufacturer.

1.1. Basic specification

TYP / TYPE

I V / S/NČ

ROK VÝROBY / PRODUCTION YEARBAUJAHR / ANNÉ DE FABRICATION

AMMANN CZECH REPUBLIC a.s.NOVÉ MĚSTO NAD METUJÍ, CZECH REPUBLIC

VÝKON MOTORU / ENGINE OUTPUTMOTORLEISTUNG / PUISSANCE DU MOT.

PROVOZ. HMOTNOST / OPERAT. WEIGHTBETRIEBSMASSE / POIDS DE SERVICE

MAX. HMOTNOST / MAXIMUM WEIGHTMAX. MASSE / POIDS MAX

MADE IN CZECH REPUBLIC

ZAT. PŘEDNÍ OSY / FRONT AXLE LOADBELASTUNG DER CHARGE DE ESSIEN ARANT

VORDERACHSE

ZAT. ZADNÍ OSY / REAR AXLE LOADBELASTUNG DER HINTERACHSECHARGE DE ESSIEN ARRIÉRE

kg

kg

3171

3171

TYP / TYPE

IČV / S/N

ROK VÝROBY / PRODUCTION YEARBAUJAHR / ANNÉ DE FABRICATION

AMMANN CZECH REPUBLIC a.s.NOVÉ MĚSTO NAD METUJÍ, CZECH REPUBLIC

VÝKON MOTORU / ENGINE OUTPUTMOTORLEISTUNG / PUISSANCE DU MOT.

PROVOZ. HMOTNOST / OPERAT. WEIGHTBETRIEBSMASSE / POIDS DE SERVICE

MAX. HMOTNOST / MAXIMUM WEIGHTMAX. MASSE / POIDS MAX

MADE IN CZECH REPUBLIC

ZAT. PŘEDNÍ OSY / FRONT AXLE LOADBELASTUNG DER CHARGE DE ESSIEN ARANT

VORDERACHSE

ZAT. ZADNÍ OSY / REAR AXLE LOADBELASTUNG DER HINTERACHSECHARGE DE ESSIEN ARRIÉRE

kg

kg

3172

3172

11AV 80 X4

400103

21

3

400102

SPECIFICATION MANUAL

Placing of the production label

1 - Production label

2 - Machine’s production number

3 - Label of the ROPS cabin

Cummins engine serial number

12 AV 80 X4

A

L

S

H4

S

D

400104

1.2. Machine dimension scheme

A D H1 H2 H3 H4 L O

mm 3260 1150 3012 2300 755 240 4410 45

in 128,4 45,3 118,6 90,6 29,7 9,4 173,6 1,8

R1 R2 R3 S W1 W2 W3

mm 6410 4600 6050 20 1600 1730 180

in 252,4 181,1 238,2 0,8 63,0 68,1 7,1

13AV 80 X4

400105

O

H1

W1

W2H

3

H2

W3

R1

R3R2


14 AV 80 X4

1.3.1. Weights

Working weight with the cab ROPS

according to EN 500 - 1 kg (lb) 7910 (17438)

front drum kg (lb) 4025 (8873)

rear drum kg (lb) 3885 (8864)

The service weight of the machine according to EN 500-1 is the machine weight with the full content of working liquids, half content of propellants, half content of sprinkling tanks and with an operator (75kg/165lb).

The machine weight according to ISO 6016 is the weight with full content of propellants, lubricants, sprinkling tanks and an operator (75kg/165 lb). It is calculated by adding 590kg (1300 lb).

The weight data can differ from above mentioned data according to the further customers’ requirements for the machine’s equipment and accessories.

1.3.2. Drive of travel - driving properties

Drive type hydrostatic

Drive front and final

Traverse speed in both directions - speed 2000 RPM - CE km/h (MPH) 10 (6,2)

Traverse speed in both directions - speed 2200 RPM - without CE km/h (MPH) 11,4 (7,1)

Theoretical machine’s gradeability % 45

Side static stability - straight frame ° 32

1.3.3. The vibrations

Drive type hydrostatic

Small frequency CE Hz (VPM) 43 (2580)

Big frequency CE Hz (VPM) 52 (3120)

Small frequency - without CE Hz (VPM) 48 (2880)

Big frequency - without CE Hz (VPM) 62 (3720)

Small amplitude mm (in) 0,35 (0,012)

Big amplitude mm (in) 0,6 (0,023

1.3.4. Engine

Manufacturer Cummins

Engine type B3,3 - C80

Number of cylinders 4

Stroke volume cm3 (cu in) 3260 (198,9)

Engine output due to ISO 3046/1 kW (HP) 60 (80)

Nominal revolutions - CE min-1 (RPM) 2000

Nominal revolutions - without CE min-1 (RPM) 2200

Maximum torsional moment Nm (ft lb) 291 (215)

Fuel consumption during common operation/hour* l (gal US) max. 10 (2,6)

Engine fulfills requirements of DIR. 97/68/EU, STAGE 2

EPA/CARB 40 CFR, PART 89 TIER 2

* - according to ACZ methodology

1.3. Technical data

15AV 80 X4


1.3.5. Brakes

Working brake hydrostatic

Parking and emergency brake mechanical lamella

1.3.6. Drive

Steering type articulated joint

Steering control hydraulic

Linear hydraulic motors 2 + 1 (Crab)

Swing of frames in vertical plane ±° 8

Turning of both frames in horizontal plane ±° 34

1.3.7. Fills

Engine (oil fill) l (gal US) 8 (2,11)

Cooling system l (gal US) 18 (4,75)

Fuel l (gal US) 110 (29,05)

Hydraulic tank l (gal US) 54 (14,26)

Drum vibrator l (gal US) 2x10 (2x2,64)

Watering tank l (gal US) 600 (158,5)

Sprinkling tank l (gal US) 2,75 (0,72)

1.3.8. Sprinkling

Sprinkling pressure

Number of pumps 2

Number of filtration stages 3

1.3.9. Electrical installation

Electric set voltage V 12

Accumulator – capacity Ah 100

16 AV 80 X4

1.3. Technical data

1.3.10. Hygienic parameters

Cabin machine:

Sound pressure level applied to the driver: LpA = 80 dB (A)

measured according to CSN EN 11 201

Guaranteed sound-power level of machine version according CE: LWA = 106 dB (A)

measured according to CSN EN ISO 3744

Weighted eguivale value of vibration acceleration transferred to the body: aw < 0,5 m.s-2 (vector sum)

measured according to CN 1032 - sand

Weighted eguivale value of vibration acceleration transferred to the hands: aw = 2,5 m.s-2 (vector sum)

measured according to ISO 5349 - sand

17AV 80 X4


Notes

18 AV 80 X4

Notes

19AV 80 X4

2. OPERATION MANUAL


20 AV 80 X4

21AV 80 X4

OPERATION MANUAL2.1. Major Safety Precautions

2.1.1. Safety Measures during Machine Operation

Safety measures given in the individual chapters of Enginering Documentation supplied with the Machine shall be added with Safety Precautions in force within a respective country that uses the Machine at workplace with regard to work organization, work process and personnel involved.

2.1.1.1. Compaction Work Commencement

Constructional Supplier (Machine User) is liable to issue in- •structions for driver and maintenance before compaction work is started, that will include requirements on work safe-ty provision during Machine operation.

He must verify and mark: •

utility lines -

underground areas (direction, depth) -

seepage or escape of hazardous materials -

soil bearing capacity, slope of travelling plane -

other obstractions incl. their removal. -

He must make Machine driver, who will carry out earth work, familiar with these conditions.

He must specify Code of Practice (C.O.P.) part of which is •work procedure for a given work operation and this work procedure will specify inter alia:

measures when working under extraordinary conditi- -ons (work within protective zones, within extreme slo-pes, etc.)

precautions for any natural disaster hazards -

requirements on work performance while observing job -safety principles

technical and organizational measures to secure safety -of personnel, workplace and environment.

He must make Machine driver evidently familiar with the Code of Practice.

2.1.1.2. Work Safety Secured by User

User shall promptly communicate any damage to the utility •lines to their operator, and at same time he make measures to prevent unauthorized persons from entering endangered area.

He must ensure an employee does not work alone at a wor- •kplace. Another worker must always be in sight and within an ear-shot, who in case of accident will provide or call for help unless another effective form of monitoring or commu-nication exists.

22 AV 80 X4

2.1. Major Safety Precautions

2.1.1.3 Ensurance of safety measures by the owner

User shall provide for the Machine to be operated merely •under those conditions and only for those purposes it is technically capable for under conditions set by manufactu-rer and respective standards.

He must make sure the use of the Roller (Compacter) is used •merely in such a way and at such workplaces where there is no hazard of making damage within nearby facilities, etc.

He shall provide for regular inspection of operation, tech- •nical condition, regular machine maintenance in cycles per the Lubrication and Maintenance Manual. In cases of failing technical condition of the Machine to such an extent it po-ses hazard to safety of operation, persons, property or cau-ses damage or impairs the environment, then the Machine must be put out of operation until a defect is repaired.

He must specify who and what tasks may carry out under •operation, maintenance or repair of the Machine.

Any who drives the Machine (driver) and anybody who per- •forms Machine maintenance or repairs must get familiar with the guidelines given in the Machine Operation Manual.

He shall provide for fire extinguisher to undergo regular in- •spections.

He must ensure the “Machine Operation Manual” and Ope- •ration Logbook are stowed at certain place inside seat box so always available to the driver.

He shall furnish constant supervision by an appointed per- •son during Machine operation under traffic on public roads, and he will in particular be liable to release instructions on securing the work safety.

He must secure the removal of hazardous materials (fuel, oil, •cooling liquid, brake fluid, etc.) from where these are spilled depending on their nature so as to avoid their adverse im-pact against environment, operation safety and persons’ health.

2.1.1.4. ROPS Cab

The ROPS cab must not be deformed and must not show •signs of corrosion, cracks or breaks. It must be fixedly con-nected to the machine frame. No additional adjustments of the cab may be performed without approval of the ma-nufacturer as such adjustments can cause a reduction in its strength. The screwed connections must comply with the specification and must be tightened to the specified torque, must be neither damaged nor deformed, and must not show signs of corrosion.

23AV 80 X4

OPERATION MANUAL

2.1.2. Reguirements on Driver’s Qualification

Only a driver trained under ISO 7130 and other local and na- •tional regulations designed for drivers of this group of ma-chines may operate the Roller (Compacter).

With no licence only the one who learns driving the Machi- •ne for the purpose of getting preliminary practice with the approval of User may drive the Machine, and such person has to be under direct and continuous surveillance of pro-fessional teacher or trainer.

Licence holder is liable to take due care of the licence, and •when requested, put it forward to the control authorities.

Licence holder can make no registrations, changes or corre- •ctions in the licence card.

He/she is liable to promptly report his/her licence loss to the •authority that issued this licence.

Driving the Roller alone may be performed by an employee •mentally and physically fit, over 18 years old, who is:

a) assigned by machine manufacturer for the assembly, testing and presentation of the Machine, for training the drivers, whereas he/she must be made familiar with safety work regulations in force at the workplace

or

b) assigned by Constructional Supplier to operate (carry out maintenance) and is evidently trained and acquainted with, or owns professional competence to operate and drive under special regulations (machinist licence, etc.).

Machine driver must undergo training and examination con- •cerning work safety regulations at least 1x every 2 years.

2.1.3. Driver’s Liabilities

Before starting to operate the Machine the driver will be •liable to get familiar with the guidelines given in the docu-mentation delivered with the Machine, with safety precauti-ons in particular, and observe these thoroughly. This applies as well to the personnel in charge of maintenance, adjust-ments and repairs of the Machine.

Do not drive the Roller unless made familiar with all the Ma- •chine functions, working and operating elements, and un-less knowing exactly how to control the Machine.

Follow safety signs located on the Machine, and keep them •in legible condition. Replace or add those impaired or mis-sing ones.

Before work commencement the driver must get familiar •with the workplace environment, i.e. with the slopes, utility line system, with necessary types of workplace protections with regard to the environment (noise, etc.).

When finding out any health hazard, life hazard to persons, •hazard to property, failures, during hardware accidents, or when finding symptoms of such hazards during operati-on, the driver must, unless able to remove such hazard by himself/herself, stop his/her work and secure the Machine against undesired starting, communicate this to a person accountable, and depending on chances, notify all the per-sons exposed to such hazard.

Before Machine operation startup the driver will be liable to •get familiar with the records and operation deviations found out in course of the previous work shift.

Before work is started he/she must inspect the Machine, its •accessories, check up control elements, communication and safety devices, whether these are operable in line with the Manual. When finding out a malfunction that might be ha-zardous to job safety, and he/she is not able to repair it, then he/she must not start running the machine and instead re-port such failure to the person accountable.

During work with the Machine the driver must be fastened •with the seat belt. The seat belt and its mounting shall not be damaged!

When driver finds any defect during operation he/she must •immediately stop the Machine, secure it safely against un-desired ignition.

During operation the driver shall follow the Machine run •and record any defects found in the Operation Logbook.

Driver shall keep his/her Operation Logbook designed to •maintain records about Machine handover between the dri-vers, about the defects or repairs in course of operation, to write down major events during work shift.

Prior turning on the engine the controls have to be in their •zero position, no persons may stay within dangerous reach of the Machine.

Indicate each Machine startup via an acoustic or light signal •and this always before igniting the Machine engine.

Confirm brake function and steering function before star- •ting to run the Machine.

Following the alarm an operator may start the Machine only •when all the workers have left the danger area. At close (blind) workplaces it will be possible to start the operation only after a time necessary to leave danger area has elap-sed.

24 AV 80 X4


During Machine operation observe safety regulations, make •no action that might endanger work safety, give full attenti-on to Machine steering.

Respect Code of Practice or instructions of a person respon- •sible.

When rolling (traversing) the Machine within a workplace •adapt your speed to a terrain condition, to a work perfor-med and weather conditions. Watch permanently the clea-rance so to avoid collision with any obstruction.

Upon completion or stop of the Machine operation during •which driver leaves the Machine, he/she must make mea-sures against unauthorized use of the Machine or against spontaneous starting the engine. Remove key from the ig-nition box, disconnect the wiring via disconnector, lock the cabin, engine bonnet.

When shutting down the Machine on roads the measures •under regulations effective on roads shall be taken.

When operation is completed, park the Machine at a proper •parking place (flat, bearing area) so as not to endanger Ma-chine stability, not to make the Machine interfere with traffic roads, not to expose the Machine to falling objects (rock), and where the Machine is safe against any natural disaster of other kind (floods, landslides, etc.).

When working with the Machine is ended all the defects, da- •mage to the Machine and any repairs made shall be written down in the Operation Logbook. Upon immediate changing of drivers the driver will be liable to call attention of chan-ging driver to any facts identified.

Driver shall use personal protective equipment (PPE) – work •clothing, safety shoes, the clothing shall not be too loose, impaired, hair protected with proper head piece. During maintenance (lubrication, refilling, replacement of working media) your hands must be protected with proper gloves. Use proper muffs when using Machine with no cabin or with open windows.

Driver shall maintain the Machine equipped with fittings •and outfit required.

Maintain the Machine free of oil dirt or flammable materials. •Keep the drive’s stand, foot rests and runner areas clean.

When the Machine comes into contact with high voltage •observe the following principles:

try to leave with the Machine a hazardous zone -

do not leave driver’s stand -

give warning to others to keep off and not touch the -Machine.

25AV 80 X4

OPERATION MANUAL

2.1.4. Banned Operations

Banned are the followingTo use the Machine following ingestion of alcoholic bewe- •rages or dopes.

To use the Machine if its operation might put its technical •condition, safety (life, health) of persons, facilities or objects, or road traffic and its continuity, at risk.

Put into operation and use the Machine when other persons •are within its hazardous reach – exception is training a driver by lector.

Put into operation and use the Machine when some of its •safeguarding device (emergency brake, driving brake, horn, etc.) has been dismantled or damaged.

To roll and compact at such slopes where Machine stability •would be disrupted (turning over). Machine’s static stability stated will lower by drive’s dynamic effects.

To roll and compact at such angles of slopes where hazard •of soil breaking off (dropping) under the Machine exists, or loss of adhesion followed by uncontrolled slip might occur.

To control the Machine in some other way than stated in Dri- •ving Manual.

To roll and compact per bearing capacity of subsoil at such •a distance from the edge of slope or trenches, where hazard of landslide or shoulder breaking off (dropping) together with the Machine would occur

To roll and compact with vibration at such a distance from •the walls, cuts, slopes, where their slip (slide) would happen and the Machine covered in.

To compact with vibration at such a distance from buildings •or facilities and equipment within which the risk of them be-ing damaged due to vibration transfer impact, would occur.

To operate the Machine unless driver control stand fixed •properly.

To operate the Machine when engine bay cover is open. •

To move and transport persons on the Machine. •

To operate the Machine when within hazardous reach the- •reof are other machines or transportation means aside from those that operate in mutual concert with the Machine.

To operate the Machine at places impossible to see from dri- •ver’s stand, and where hazard to people or property could occur unless work safety has been secured through some other way like for instance via signalling by duly instructed person.

To work with the Machine at a protected zone of electric li- •nes or substations.

To cross electric cables if these are not properly protectedli •against mechanical damage.

To operate the Machine under lowered visibility or at night, •unless Machine’s working area and workplace are illumina-ted sufficiently.

To leave driver’s cockpit of the Machine when the Machine •is running.

Boarding or or getting off while on the run, jumping off the •Machine.

Sit or stand on the outside parts of the Machine when dri- •ving, or stand on the steps.

Leave unsecured Machine – move away from the Machine •

without having prevented its misuse.

Disable safeguarding, protective or locking systems or alter •their parameters.

Use the Machine with oil, fuel, cooling liquid or other fillings •leaking.

Start the engine through some other way than given in the •Driving Manual.

Locate some other items (tools, accessories) aside from per- •sonal needs at driver’s stand.

Lay away material or other objects on the Machine. •

Remove dirt while the Machine is running. •

Perform maintenance, cleaning or repairs with the Machine •not secured against spontaneous move or accidental start, and when contact of a person with moving parts of the Ma-chine is not excluded.

Contact of moving parts of the Machine with human body •or objects and tools held in hands.

Smoke or handle open fire when checking or pumping fuels, •refilling oils, lubricating the Machine, or inspecting the accu-mulator or making up the accumulator.

Carry rags soaked with flammable materials, or carry flam- •mable liquids in free vessels on the Machine (in engine bay).

Let the engine run inside confined spaces. •

26 AV 80 X4

2702bz

2428

2687bz

2687

2941bz

2942bz

2584bz


2.1.5. Safety inscriptions and signs used on the Machine

1. Read Operation Manual! Get perfectly well familiar with the Machine operation and its maintenance per the Operation Manual! (Symbols located on the LH side of the control console )

2. Handbook The Operation Manual stowage box (symbol located at the rear on the stowage box at the seat )

3. Fasten your seat belt! Fasten your seat belt before driving! (symbol located on the left on the control panel )

4. Clamping hazard Maintain safe distance from the Machine, danger of being clamped by the Machine in between the front and rear frame. (symbols located on the left and right near steer-ing joint .

5. Danger area Maintain safe distance! (symbol located on the left and right, on the front frame)

Maintain safe distance from the cutter and final compac-tor if running. (symbol located on the RH front yoke – op-tional

6. Adjust while at rest Adjust and maintain with the engine stopped. (symbol located on the left, on the rear frame )

27AV 80 X4

3322bz

2586bz

3292bz

3292

3201BZ

3326bz

3017bz

OPERATION MANUAL

7. Risk of injury Maintain safe distance. (symbol located on the fan cover)

8. Risk of burn Do not touch Machine’s hot parts unless you make cer-tain these have cooled down sufficiently. (symbol located on the LH side of the rear frame overhead exhaust pipe )

9. Bonnet lifting – adjust at rest Lift the bonnet with the engine switched OFF. (symbol located on the left, on the rear frame )

10. Bonnet lifting Pump to lift the bonnet. (Symbol located on the left, on the rear frame near door )

11. Bonnet locking Lock the bonnet (symbol located on the left, on the rear frame)

12. Danger of explosion Read the Operation Manual before any maintenance of the battery, or before starting via the jump cables. (sym-bol located on the left, on the rear frame )

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2668bz

2225bz

2225

3323bz

2411bz

2427bz

3207

3,05 m


13. Disconnect wiring Before welding, please disconnect wiring, alternator, Ma-chine’s electronics, and engine control unit. (symbol lo-cated on the LH side of the control panel

14. Electric apparatuses Cover electric apparatuses when washing the Machine. (symbol located on the LH side of control panel )

15. Cooling liquid Cooling liquid is deleterious. Scald hazard during its ex-change. Read Operation Manual! (symbol located on the cooling liquid tank )

16. Emergency exit Symbol located on the window of RH door .

17. First aid kit Designation of box designed for first aid kit (symbol lo-cated inside cabin, behind seat )

18. Machine’s max height Caution when passing locations with height limit (symbol located on the left beneath the cabin, on the Machine ) frame

29AV 80 X4

3191bzdB

WAL

106

2153bz

3048bz

3208bz

3325bz3325

8400 kg

Lmin = 5 m2x min 2100 kg(2x min 4630 lb)

Lmin = 5m2x min 2100 kg(2x min 4630 lb)

(18 520 lb)

OPERATION MANUAL

19. Noise emitted Machine’s external noise (symbol located on the LH side of the front frame )

20. Sling points Sling the Machine in these points only. (symbols located along both sides of both frames overhead the drum )

21. Sling points Sling the Machine in these points only. (symbols located along both sides of the frame )

22. Supporting point Locate hand jack or fixed support of the Machine here (symbol located on the front and rear frame along both sides )

23. Lifting diagram Use rigging of sufficient loading capacity to lift the Ma-chine. Secure the Machine’s joint before lifting. (symbol located on the left, on the front frame )

30 AV 80 X4

STOP

Sig. 1

!Sig. 2

!Sig. 3

Sig. 4


2.1.6. Hand Signals

Signals given by Machine assistant operator unless driver visu-ally contains the rolling space or working space or working equipment, tool.

Signals for general commands

StopOne arm erected with open palm in the direction of the driver, second arm akimbo.

AttentionBoth arms sideways raised horizontally – palms forward.

Attention, DangerSwinging motion of both of the arms with antebrachium from the position of arms sideways raised horizontally to the position of arms sideways raised – arms bending across and back.

SIGNALS FOR DRIVE

Departure with the MachineOne arm erected – bent with open palm, long motion of an-tebrachium in the direction of required motion, second arm akimbo.

31AV 80 X4

Sig. 5

Sig. 6

Sig. 7

Sig. 8

OPERATION MANUAL

Low-speed cruising forward – towards meBoth arms erected abreast bending across, with palms towards the body – short swinging movements of antebrachium towards the body and backward.

Low-speed cruising backward – away from meBoth arms erected abreast bending across, with palms away from the body - short swinging movements of antebrachium away from the body and back.

Driving to the rightLeft arm sideways raised, right arm akimbo.

Driving to the leftRight arm sideways raised, left arm akimbo.

32 AV 80 X4

X

Sig. 9

Sig. 10

Sig. 11


Short motionBoth arms lifted forward bending across. Mark the „X“ distance between palms, then the motion signal follows.

Engine startCircular motion of right hand’s antebrachium, with the fist closed.

Engine cut offOscillating motion of right hand sideways raised in front of the body to the sides.

33AV 80 X4

OPERATION MANUAL

When operating and storaging the ma-chines a User will be liable to observe general principles of health and envi-ronmental protection, laws and regula-tions that relate to the given issue and are in force within a territory where the Machine is used.

Oil proudcts, cooling system fillings, accumulator fillings, or •painting materials incl. thinners are materials that pose he-alth hazard. Workers coming into contact with these produ-cts during Machine operation or maintenance will be liable to follow general principles of one’s own health protection, and abide by safety and hygienic guidelines of these produ-cts’ manufacturers.

We call your attention to the following in particular:

Eye and skin protection when handling accumulators -

Skin protection when handling oil products, painting -materials or cooling liquids

Washing your hands properly upon work completion or -before meals, apply a proper reparation cream on your hands

When handling cooling systems, please follow the in- -structions given in the Manuals supplied with the Ma-chine.

Always maintain oil products, cooling system and accumu- •lator fillings and painting materials incl. organic thinners and also the cleaning and preserving agents in their original properly designated packages. Do not allow storage of the-se materials in undesignaged bottles or other vessels due to the hazard of them being interchanged. Especially haza-rdous is the possibility of interchanging them with eatables or drinks.

Upon skin, mucosa, eye contacts or inhalation of vapour, im- •mediately apply the principles of first aid. Upon accidental use of these products get prompt medical attention.

When operating the Machine with no cabin provided, or •with cabin windows opened, always use ear defenders (muffs) of proper type and version.

2.2.2. Ecological Principles

The fillings of Machine’s individual systems and some of its •parts become waste with hazardous properties against the environment when discarded.

This category of waste products includes in particular:

Organic as well as synthetic lubricating materials, oil or -fuels,

Cooling liquids, -

Accumulator fillings and the accumulators themselves, -

Cleaning & preservation agents, -

All filters and filter elements dismantled, -

All used and discarded hydraulic hoses or fuel hoses, -metal rubbers and other Machine’s elements, foulded with the abovementioned products.

• Manufacturer and manufacturer-accredited contractingservice organizations or dealers take back the following used materials or parts free of charge:

Oils

Accumulators

Handle the given materials and parts following their disposal in line with the respective national regulations on pro-tection of individual components of environment, and in conformity with health regulations.

2.2. Ecological & Hygienic Principles

2.2.1. Hygienic Principles

34 AV 80 X4

2.3.1. Short-Term Preservation & Storate for the Period of 1 ÷ 2 Months

Wash and clean the entire Machine carefully. Before parking •the Machine for its preservation and storage, please warm up the engine to its operating temperature while running. Park the Machine on solid, flat surface at a safe place with no risk of natural disaster (floods, landslides, fire, etc.) to the Machine.

In addition:

Repair those spots with damaged paint, •

Lubricate all lubricating points, control cables, joints of the •controls, etc.,

Confirm water fillings are drained, •

Check that cooling liquid has antifreezing characteristics •requiered,

Check the state of accumulator charges, recharge them if •necessary,

Apply preservative grease over the chormed surfaces of pis- •ton rods,

We recommend to protect the Machine against corrosion •through spraying the preservation agent (applied spraying), and this in particular in places with potential of corrosion origin.

The Machine treated like that will need no special preparation prior to its subsequent putting into operation.

2.3.2. Machine Preservation & Storage for the Period Over 2 Months Long

To park the Machine the same principles will apply like at short-term preservation.

In addition it is recommended to:

Dismantle the accumulators, check their condition, and sto- •re in a cool, dry room (recharge the accumulators regularly),

Support the runner frame so the damping system shows •minimal sag,

Protect rubber elements through painting with spec. preser- •vation agent,

Inflate the tyres to a pressure required, and protect them •from direct sunlight,

Apply preservation grease over the chromed surfaces of the •piston rods,

Preserve the Machine via spraying with special agent, and •this at places of possible corrosion origin,

Blind the engine suction and discharge ports with double •PE foil, and tighten this foil thoroughly with adhesive tape,

Protect the headlamps, external back mirrors and other ele- •ments of external wiring through spraying a special agent and wrapping into PE foil,

Preserve the engine per Manufacturer’s Instruction Manual •– mark visibly the engine has been preserved.

After 6 months we recommend to inspect the condition of preservation and renew if required.NEVER start the engine in course of storage!In case of Machine storage under field conditions, please check the parking place whether not exposed to the hazard of flooding, and that danger of any other type is not present!

Prior to restoration of Machine op-eration, please wash the preservation agents away with the use of high pres-sure stream of hot water incl. addition of normal degreasers while observing the Instructions for Use along with ecologi-cal principles. Carry out the dewaxing (deconservation) and washing of the Machine at places equipped with intercepting sumps to trap the rinsing water as well as dewax-ing agents.

2.3. Preservation & Storage

35AV 80 X4

OPERATION MANUAL

2.3.3. De-conservation and inspection of brand new machines

Check the machine against delivery documentation. •

Check whether any parts were damaged during transport or •are missing. Inform the shipper of any discrepancies.

Before starting operations again, wash off conservation ith highpressured hot water with ordinary degreasing means added as directed, while observing envi-ronmental rules.Remove conservation and wash the ma-chine in places with catch basins availa-ble to collect rinse water and chemicals.

36 AV 80 X4

In no event shall Manufacturer be liable for damage to User health or environ-mental damage that arises from non-ob-servance of the abovementioned note.

During Machine disposal following its service life the User will be liable to follow national waste and environmental regulations and acts. We recommend to always contact in these cases:

the specialized companies with respective authorization to •deal professionally with these operations,

the Machine manufacturer or manufacturer-appointed •accredited contracting service organizations put in charge by manufacturer.

2.4. Machine Disposal Following Its Life Termination

37AV 80 X4

12

13

20

21

21

21

5

8

19101

2

9

17

16

14

15

4

3

20

1811

67

21400106

OPERATION MANUAL2.5. Machine Description

1 - Front frame

2 - Rear frame

3 - Front drum

4 - Rear drum

5 - Engine

6 - Drum travel hydroelectric generator

7 - Drum vibration hydroelectric generator

8 - Travel hydraulic motor

9 - Vibration hydraulic motor

10 - Steering joint

11 - Hydraulics tank

12 - Fuel tank

13 - Sprinkling tank

14 - Cabin with integrated ROPS arm

15 - Driver’s control stand

16 - Battery

17 - Combined engine and hydraulic oil cooler

18 - Air filter

19 - Exhaust pipe

20 - Sprinkling jets

21 - Drum scrapers

38 AV 80 X4

400107

25 26

24

13

30

0

1

2

16

111920212223

15

18

2729

5

1

28

9

10

3

4

32

5

1 7

6 6

7

31

17

1412

28

2.6. Controls & Dashboard Instruments

39AV 80 X4

OPERATION MANUAL

Dashboard and control panels 1 - Travel controls

2 – Speed potentiometer

3 – Pushbutton for mode of soft starting to move and stopping to move

4 – CRAB mode resetting switch

5 – Pushbuttons for CRAB mode – front drum, to the right*

6 – CRAB pushbuttons – front drum, to the left*

7 – Vibration pushbuttons

8 – Emergency brake pushbutton

9 – Sprinkling pushbutton

10 – Sprinkling interval potentiometer

11 – Sprinkling pumps selector switch

12 – Ignition box

13 – Accelerator control

14 – Front / both / rear vibration selector switch

15 – Vibration amplitude selector switch

16 – Vibration mode selection switch (MAN/AUT)

17 – Combined switch

18 – Switch for constant speed and protection against engine overload

19 – Beacon switch (optional)

20 – Alarm lights switch

21 – Additional lights switch (optional)

22 - Switch + indicator lamp for rear lights

23 – lndicator lamps for lights (dipped/distance)

24 – Infrathermometer (optional)

25 – LH cluster

26 – RH cluster

27 – Cut-out box

28 – Cabin fuse

29 – Diagnostics socket

30 – Mounting socket

31 – Steering wheel position adjustment

32 – Operator seat

* If the Machine is equipped with cutter and final compactor then pushbuttons (5) and (6) on the travel control (1) are used to control it, and this on the same side where it has been mounted (optional).

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400108

0

1

2

5

1

28

93

4

5

1 7

6 6

7

0 N

1

25 26

2.7. Machine basic functions control

41AV 80 X4

OPERATION MANUAL

Travel controls (1)

These controls are used to adjust travel direction and speed. Travel speed depends on the degree of swing of travel controls from zero position (0), in dependence on speed potentiometer (2) adjustment.

Travel controls have two positions, i.e. “N” and “0”:

“N” - neutral

- in this position the Machine parking brake is enabled.

“0” - zero position

- the Machine is not braked in this position.

Neutral position (N) is signalled through lighting up of neutral and parking brake indicator lamps on the cluster (25).

Located on the travel control are vibration ON/OFF pushbuttons (7) and pushbuttons (5), (6) to control in CRAB mode.

If the Machine is equipped with cutter and final compactor then pushbuttons (5) and (6) on travel control are used to control it, i.e. those on the same side where it is mounted (optional).

Engine start is possible only in neutral position (N).

Speed potentiometer (2)

Potentiometer is used to smoothly select speed mode within the range from min speed of “turtle” to max speed of “rabbit”. When adjusting potentiometer speed in any position you may always enable vibration function.

Machine will not move with speed potentiometer set to MIN position.

Switch for the mode of soft starting to move (dri-veaway) and stopping to move (stopway) (3)

3317

3317

2685

3128

It is used to adjust soft starting to move and stopping to move when stopping and reversing the Machine. In this way the crea-tion of “waves” on compacted surface will be eliminated. Press the switch to enable the function, and indicator lamp on cluster (26) will go ON.

Attention, in this mode the Machine stopping distance is longer!

Switch for CRAB mode resetting (4)

3319

Press this switch to adjust front drum in CRAB mode.

CRAB mode resetting is signalled by indicator lamp on cluster (26) going OFF.

Steer angle of the front drum in CRAB mode – yel-low pushbuttons (5) and (6)

Press pushbuttons on travel controls (1) to steer in CRAB mode

Pushbutton (5) – front drum to the right

Pushbutton (6) – front drum to the left

Indicator lamp on cluster (26) goes ON to signal this function.

NoteIf the Machine is equipped with cutter and final compactor then it will be controlled via pushbuttons (5) and (6) on travel con-trol (1), and this on the same side where it has been mounted (optional).

2721

Vibration ON / OFF pushbuttons (7)

Press these buttons to turn ON/OFF this function. Indicator lamp on cluster (25) will go ON.

Sprinkling button (9)

3183

2582

Emergency brake (8) pushbutton

Press this button to enable Machine’s emergency brake, and in-dicator lamps on cluster (25) for brakes, recharging, neutral, and engine oil pressure will light up.

Engine will stop and stall!

Hold down this pushbutton to enable drum additional sprin-kling function. Indicator lamp on cluster (26) will light up.

42 AV 80 X4

400109

25 26

13

0

1

2

15

10

17

1412

11 1623


43AV 80 X4

OPERATION MANUAL

Sprinkling interval potentiometer (10)

Swing the sprinkling potentiometer from „MIN“ to „MAX“ posi-tion to control smoothly drum sprinkling intensity.

Sprinkling function will not be enabled with the sprinkling potentiometer set to MIN position.

Pumps sprinkling selector switch (11)

One of two drum sprinkling pumps will turn ON, and indicator lamp on cluster (26) will light up.

Adjust sprinkling potentiometer before switching ON the pump!

3186

3181

Ignition box (12 )Ignition box has three positions of „0-I-II“. The key can be insert-ed and removed in ”0” position only.

Turn a bit the key to RH side to enable first the ”I” position and then ”II” position.

”II” position is used to start the engine.

Protect ignition box with cover once the key is pulled out.

Accelerator control (13)

2406

It is used to adjust combustion engine rpm ranging from idle to max speed. Move the accelerator control towards operator seat to increase the rpm and vice versa. Accelerator control is connected with the engine injection pump control lever via a cable.

Drum vibration selector switch (14)3179

The selector switch has three positions:

Left – front drum vibration

Centre – both drums’ vibration

Right – rear drum vibration

Vibration amplitude selector switch (15)

2682

The selector switch has three positions:

Left – low amplitude switched ON

Centre - OFF

Right – high amplitude switched ON

MAN / AUT vibration mode selector switch (16)

3180

It is used to switch ON vibrations in MAN or AUT mode.

MAN – manual mode, vibrations can be switched ON even with stationary Machine.

AUT – automatic mode to switch OFF/ON vibrations

Cluster (17)It is used to turn ON/OFF contour lights, dipped lights, distance lights, traffic-indicator lights and horn.

Indicator lamps (23) light up to signal contour, dipped, and dis-tance lights are ON.

Indicator lamp on cluster (25) lights up to signal traffic-indicator lights are ON.

44 AV 80 X4

400110

24

0

1

2

1920212223

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2

1 1

13

12

25 26


45AV 80 X4

OPERATION MANUAL

Switch for constant speed and protection against engine overload (18)

3185

0

Constant speed function:It is used to maintain constant speed of the Machine when driv-ing on flat surface, uphill, or downhill.

When control unit is switched ON the indicator lamp on cluster (26) signals this function.

The driving speed corresponds to the degree of swing of travel control (1) from neutral position (0), depending on speed poten-tiometer (2) adjustment.

ANTISTALL function It is used to protect the engine on steep grade or the Machine not to sink in ground.

With the control unit switched ON the indicator lamp on cluster (26) will signal this function. The control unit will automatically lower the power take-off (PTO) through reducing the set speed (rpm of travel hydraulic motor) independently on travel control position. Thus the tractive force (of travel hydraulic motor) will increase - engine will get relieved.

Adjust engine max rpm by means of ac-celerator control (13) before turning ON the switch!When a hard terrain has been overcome, turn OFF the switch!

Switch + hazard beacon indicator lamp (19) - (optional)

592348

It is used to switch ON/OFF hazard beacon, indicator lamp in the switch signals this function.

Alarm lights switch (20)

AMN24

It is used to turn ON/OFF alarm lights - indicator lamp in the alarm lights switch and on clusters (25) and (26) will flicker to signal this function.

Switch + indicator lamp for cabin’s additional lights (21 )

596473

It is used to switch ON/OFF additional lights, indicator lamp in the switch signals this function.

Switch + indicator lamp rear lights (22)

591668R

It is used to turn ON/OFF rear lights, indicator lamp in the switch signals this function.

Indicator lamps for (dipped / distance) lights (23)

591508

These lamps signal dipped or distance lights switched ON.

Infrathermometer (24) - (optional)

3044

It will be enabled through the key turned ON in the ignition box (12) and it will measure through temperature sensor for a bitumen surface rolled. The value measured is indicated in C° degrees on display (24).

46 AV 80 X4

400501

478320h

25


LH cluster (25)

Fuel consumption gauge

AMN25

It signals current fuel level in the tank, when emptied to min the red LED will flicker.

Counter of motohours actually worked

It will display the number of motohours the engine was running. With the engine started the counter will begin counting the mo-tohours.

NoteCounting the number of motohours does not depend on en-gine rpm.

Parking brake indicator lamp

The indicator lamp ON will signal the parking brake has been enabled.

AMN26

AMN1

AMN2

Seat switch indicator lamp

Indicator lamp will light ON when operator is not sitting on the seat or when emergency brake has been enabled.

Indicator lamp for hydraulic oil pressure filter fouled

AMN3

Indicator lamp ON signals filter element is fouled.

Immediately replace the filter element!

Battery recharging indicator lamp

Unless indicator lamp goes OFF, find a defect!

Indicator lamp lighted ON during engine run will signal a de-fect. Following 5 seconds the acoustic alarm will start, and after 2 minutes the engine will stall automatically – the Machine will stop and parking brake will be enabled.

Check fuel level during Machine operation.

Engine can be started once its defect has been repaired!

It signals proper function of battery recharging. When switching the key on the ignition box (12) over to “I” position the indicator lamp shall go ON and following the start it must go OFF.

AMN4

47AV 80 X4

OPERATION MANUAL

Indicator lamp for air filter fouledAMN5

Indicator lamp ON signals filter element is fouled above a limit admissible.

Stop the Machine and replace the filter element instantly!

Engine lubrication lamp

AMN6

When switching the key in the ignition box (12) over to “I” posi-tion and indicator lamp shall go ON, and when engine is started it must go OFF.


Stop the Machine and check oil amount or find a defect!

Indicator lamp for engine overheated

This indicator lamp signals the cooling liquid’s max temperature allowed has been exceeded.


Stop the Machine and check cooling liq-uid amount, or find out any defect!

AMN7

Indicator lamp for traffic-indicator lights

AMN8

Indicator lamp ON will signal traffic-indicator lights are ON, or alarm lights have been turned ON.

Neutral indicator lamp

AMN9

Indicator lamp ON will signal the position of travel controls is in neutral (N).

Before starting the engine the travel controls (1) shall be in neu-tral position (N)!

Indicator lamp that the vibration is ON

AMN10

Indicator lamp ON will signal the vibration is ON.

Indicator lamp for hydraulic oil temperature

Indicator lamp signals max hydraulic oil temperature admissible has been exceeded.

Stop the Machine and check oil level or find a defect!

AMN12

Check hydraulic oil level

AMN11

Indicator lamp signals low hydraulic oil level.


Engine can only be started when failure is repaired and oil in hydraulic tank re-filled to a limit specified!

48 AV 80 X4

400502

26


49AV 80 X4

OPERATION MANUAL

RH Cluster (26)

Level height in sprinkling tank.

AMN27

It signals the actual level of water in the tank, and when emptied to min the red LED will start to flash.

Cooling liquid indicator lamp


Engine can only be started when failure is repaired and cooling liquid refilled to a limit specified!

Air conditioner indicator lamp

Indicator lamp signals air conditioner is ON (optional).

AMN14

CRAB mode indicator lamp

Indicator lamp signals the front run is set to CRAB mode.

AMN15

Indicator lamp for soft starting to move and stop-ping to move

Indicator lamp ON signals the mode of soft starting to move and stopping to move is ON.

Intermittent flashing of this indicator lamp signals an error code for a defect within Machine travel system.

Shut down the Machine and call service organization in respect of failure repair on the Machine travel system!!!

AMN16

ASC indicator lamp

AMN17

Not connected.

Fuel filter indicator lamp

AMN18

Indicator lamp lighted ON signals water presence in fuel filter.

Engine glowing indicator lamp

AMN19

Not connected.

Spreader indicator lamp

AMN20

This indicator lamp signals the spreader is ON (optional).

Indicator lamp to protect against engine over-load (ANTISTALL)

AMN21

This indicator lamp signals the ANTISTALL is ON.

Sprinkling pump indicator lamp

AMN22

Indicator lamp signals sprinkling pump is ON.

Constant speed indicator lamp

This indicator lamp signals the constant speed mode is ON.

AMN23

Alarm lights indicator lamp

AMN24

This indicator lamp signals alarm lights are ON.

AMN13

Check water level in the tank during Machine run.

If this indicator is ON, please clean the fuel filter!

50 AV 80 X4

400116

27

400118

400119

400117


Cut-out box (27)

It contains F1 - F8 fuses.

F1 - 20 A front, rear headlamps

F2 - 15 A roof lights, light switches

F3 - 15 (30)A traffic-indicator lights, horn, beacon, extra lights, mounting socket

F4 - 5 A clusters

F5 - 10 A travel electronics, backing horn

F6 - 15 A sprinkling

F7 - 7,5 A vibrations, CRAB (trimmer)

F8 reserveOther fuses located on the Machine At battery disconnector

F9 radio (as per car radio manufacturer)

Under the cabin lighting cover

F11 - 15 A wipers + window washers

F12 - 15 A fans

F13 - 5 A fan control + air conditioner control

F14 - 10 A air conditioner

51AV 80 X4

28

400116A

29

30

A

400125

A

400126

OPERATION MANUAL

Cabin fuse (28)F15 - 30 A cabin wiring

Steering wheel positioning (31)It is used to facilitate boarding and leaving the Machine by its operator.

Release lever (A) to position the steering wheel in the direction away from the column axis towards a dashboard.

The lever (A), when shifted out, can be arrested in any position.

Always replace the fuses with the ones of identical value!

Diagnostics socket (29)It is used to check and set the control units’ parameters via exter-nal computer units (notebook).

Mounting socket (30)It is used to connect auxiliary inspection lamp (12V).

52 AV 80 X4

400253

3

45

1

2

6

400122

400124MAX 40°


Operator seat (32)

Seat adjustment:1 Backrest position

2 Arm support position and lifting

3 Seat turning

4 Seat shifting

5 Seat springing stiffness according to weight indicator.

6 Seat height – grasp the seat and lift slowly to adjust seat height in its next higher position and lock it there. Once lifted to its highest position, the seat will drop back to its lowest position.

Adjust your seat before driving !Driver must be fastened with the seat belt while driving!

How to swivel operator’s place:Operator’s place can be swivelled within the range of 40° when accelerator pedal is pressed. Once the pedal is released the op-erator’s place is locked (arrested) in one of 4 positions.

Seat switch:Seat switch is located in its cushion.

Description of seat switch function:It is used to interlock the engine starting or to stop the Machine if no operator sits on the seat.

Interlocking of engine starting:When operator is not sitting on the seat the Machine cannot be started.

Machine stopping:If operator stands up from the seat while driving then the Ma-chine will stop following 8 seconds.

Machine starting to move:Its operator must sit down on the seat and shift the travel con-trols (1) to neutral (N) and then select direction of running.

Do NOT load seat switch with other objects!

53AV 80 X4

400123

3435

33

400120

37

400120A

37

36

OPERATION MANUAL

Documentation stowage box

2428

The locker for documentation is located on the seat’s rear side.

Front wiper selector switch (33)Three-position selector switch

Turned OFF -

Low speed ON -

High speed ON -

Glass washer switch (34)Two-position selector switch

Windscreen washing ON -

OFF -

Rear window washing ON -

Fan switch (35)It is used to switch ON cabin fan, its function is signalled via indi-cator lamp in the switch.

OFF -

High delivery ON -

Low delivery ON -

Cabin lighting (36)Ceiling lamp incl. selector switch is located overhead the dash-board.

Ventilation nozzles (37)Adjustable nozzles are located on cabin ceiling, please adjust and swivel the dampers to alter the amount and direction of flowing air.

54 AV 80 X4

400121

3840

39

400241

400121A


Control tie rod for heating valve (38)It is used to switch ON the cabin heating.

Make continuous control from MIN position (valve closed) to MAX position (valve fully open) for the amount of liquid flowing to the heating body.

Adjust the heating valve before driving!

Hand pump control lever (39)It is used to control the hand pump when lifting or letting down the bonnet.

First-aid box stowage place (40)

Fire extinguisher (41) - (Optional)The way of using fire extinguisher is described on the apparatus package.

We recommend to equip the Machine with fire extinguisher!Make yourself familiar with the applica-tion of fire extinguisher !Carry out regular inspections of the fire extinguisher!

Stowage pockets (42)These are used for Operator’s personal items.

The Machine shall be equipped with first-aid box!

55AV 80 X4

400127

400242

400258

400243

OPERATION MANUAL

Anti-dazzle (sun) screen (43)Adjust the anti-dazzle screen through securing it to the fixing on the glass.

Window washer tank (44)Fill with standardly available media.

Fill with antifreeze or drain before winter season starts!

Additional lights (45)Lights located on the Machine cabin (optional).

Beacon socket (46)It is used to connect the beacon.

Back mirrors (47)External back mirrors enable to view poorly visible areas.

Maintain these mirrors clean and prop-erly adjusted!

56 AV 80 X4

400234

1

400244

400245

400246

„0“ „I“


Cabin ventilation air filter (48)It includes replaceable filter element to catch the impurities drawn in from air.

Arm rests on the door (49)Transportation position

Battery disconnector (50)It is used to disconnect the battery from the Machine frame.

Position „0“ – Machine wiring disconnected.

Position „I“ – Machine wiring connected.

Working position

57AV 80 X4

400257

OPERATION MANUAL

Hand pump (51)It is used to lift or let down the bonnet.

Located on LH side of rear frame.

58 AV 80 X4

400113

25 26

13

0

1

2

8

1

17

12

1

0 N

1


59AV 80 X4

OPERATION MANUAL

2.7.1. Engine starting

Check daily before engine starting the amount of oil in the engine and hydraulic tank, cooling liquid in the cooling circuit, fuel in fuel tank, water level in water tank. Confirm no loosened, worn or missing parts exist on the Machine.

Start the engine only from the driver’s control stand! Use alarm horn to signal the engine starting and check nobody is endangered by starting the engine!

How to start:Switch ON the battery disconnector (50). •

Insert key in the ignition box (12) in “0” position and switch over to “I” position. •

All indicator lamps on clusters (25 and 26) will light up. •

Then on cluster (25) the indicator lamps for brakes, recharging, neutral, will remain ON, along with engine lubrication indicator •lamp (flickers).

If you leave the key in ”I“ position for over 15 seconds then the acoustic alarm will switch ON – to warn operator about the battery •discharged (acoustic alarm will turn OFF once engine is started). Unless it is started within 2 minutes, please get your key back to “0” position before starting the engine again.

Use alarm horn on combined switch (17) to signal engine starting. •

Adjust accelerator control (13) for increased rpm (1/4 stroke). •

Turn the key to “II” position to start the engine. •

On cluster (25), following the starting, the engine lubrication indicator lamp and recharging indicator lamp shall go OFF. •

Once the Machine has started to move the neutral lamp and brake lamp will go OFF. •

NoteIf starting is unsuccessful, please turn your key back to ”0“ position. Unless engine starts even after 3 attempts – please check the oil system.

Starting is interlocked:unless travel controls (1) are in neutral position (N) -

emergency brake (8) function is enabled. -

Do NOT start the engine for over 30 seconds. Wait 2 minutes before any next starting.When starting at low temperatures the recharge indicator lamp will remain ON accompanied by a sound alarm – increase engine rpm adequately – the indicator lamp will go OFF.Following the engine start let the engine idle at increased rpm (1/2 stroke of accelerator actuator) for 3÷5 min. Steep rpm increase or decrease is inadmissible – it may damage the engine.Do NOT let the engine idle for over 10 minutes – any idling longer then that may cause fouling of injec-tors, piston rings, or valves to get seized!Unless oil temperature reaches min. 60 °C, then the engine will not be lubricated sufficiently – do not load the engine fully!

60 AV 80 X4

012V

-+

3

+

-2

1

412V0

400131


61AV 80 X4

OPERATION MANUAL

How to start via cables from external power source:

Starting voltage from external power source shall be the voltage of 12V.Follow unconditionally the operation sequence below.

1/ Connect one end of (+) cable pole to (+) pole of the battery discharged.

2/ Connect second end of (+) cable pole to (+) pole.

3/ Connect one end of (–) cable pole to (–) pole of external battery.

4/ Connect the second end of (–) cable pole to such part of started Machine which is fix-wired with the engine (or with the engine block itself ).

When started, disconnect the battery jump cables in reverse order.Do not connect (–) pole cable to (–) pole of discharged battery of the Machine being started! There is risk of strong sparking in course of starting followed by explosion of battery-generated gas.Make sure the non-insulated parts of the battery jump cable clamps do NOT contact each other!Make sure the jump cable connected to (+) pole of the battery does NOT come into contact with electri-cally conductive parts of the Machine – danger of short circuit!Do NOT lean over the battery – risk of electrolyte burn!Rule out any presence of flammable sources (open flame, burning cigarettes, etc.)Do NOT confirm voltage presence in a wire through sparking via Machine frame!

62 AV 80 X4

400114

13

0

1

2

2

3

1 1

26

0 N

1


63AV 80 X4

OPERATION MANUAL

2.7.2. Machine travel and reversing with no vibration

Before starting to move, please check the area in front and behind the Machine is clear and with no persons or obstructions present!Use loud horn to signal engine starting and wait long enough for those persons present to leave the in time the area round the Machine or the area beneath the Machine!Operator must sit on the seat before the Machine starts moving! If the operator gets up from the seat during the Machine travel then the Machine will stop and brake.

Machine travel and reversation:Select travel direction:Start the engine. Adjust max engine rpm via accelerator control (13)

Get the Machine moving by shifting travel controls (1) from (N) zero position to (0) neutral position and then by selecting a direction of running.

Shift the controls (1) to opposite direction to change the direction of Machine travel.

Travel speed selection:Travel speed corresponds to the deflection magnitude of travel controls (1) from zero position (0).

Travel speed can continuously be altered using speed potentiometer (2) within the range of MIN (turtle) to MAX (rabbit).

If the speed potentiometer (2) is in MIN position then the Machine is unable to start moving.

NoteThe instantaneous stopping of the Machine by means of travel controls (1) applies to all travel modes of the Machine.

Shift the travel controls (1) to opposite position via (0) and then return to (0) position within the interval of 1 second to stop the Ma-chine – the engine will continue to run.

Travel modes of the Machine:RAMP (soft starting to move and stopping to move) •

CONSTANT SPEED (continuous Machine drive) •

ANTISTALL (engine protection against overload) •

CRAB (extended track of the Machine) •

Travel in RAMP modeThe function of soft starting to move or stopping to move prevents from forming the waves when compacting the bitumen surface during Machine travel.

Attention, in this mode the Machine stopway is longer!

Use speed potentiometer (2) to adjust the speed, and use travel control (1) to adjust travel direction.

Press pushbutton (3) to switch ON/OFF this function, indicator lamp on cluster (26) will light up to signal this function.

Move travel controls (1) to opposite position via (0), and then return it back to (0) position within 1 second interval to stop the Machine – the engine will remain running.

Following the travel controls (1) moved to neutral (N) the function will be OFF!

Shift travel controls (1) to neutral (N) position, press pushbutton (3) – the function will become enabled again.

NoteYou may switch ON the function during Machine travel.

64 AV 80 X4

400130

13

0

1

2

2

3

1 1

26

18

0 N

1


65AV 80 X4

OPERATION MANUAL

Travel in CONSTANT SPEED modeThis function is used to maintain continuous travel while the Machine is ascending or descending.

Use speed potentiometer (2) to adjust travel speed and use travel controls (1) to adjust its direction.

Use switch (18) to turn ON/OFF the function, indicator lamp on cluster (26) will light up to signal this function.


Swivel the travel controls (1) from position (0) and the Machine will start moving.

NoteThe function can be turned ON during Machine travel.

Travel in ANTISTALL modeIt is used to protect against engine overload on steep grade or with the Machine sunk.

Control unit will automatically reduce the power take-off through lowering the set rpm (rpm of travel hydraulic motor) independently of travel control position. Thus the pulling power (of the travel hydraulic motor) will increase – the engine will get relieved.

Switch OFF the function of soft starting to move and stopway via switch (3) if this function is turned ON!Before turning ON the switch (18), please use accelerator control (13) to adjust engine’s max rpm!

Use speed potentiometer (2) to adjust travel speed, and use travel controls (1) to adjust its direction.

Use switch (18) to turn ON/OFF this function, the indicator lamp on cluster (26) will light up to signal this function.


Swivel travel controls (1) from (0) and the Machine will start moving.

AMN23

AMN21

When having overcome a difficult terrain, please turn OFF the switch!

66 AV 80 X4

400132

0

1

2

2

1

26

4

556 6

1

0 N

1


67AV 80 X4

OPERATION MANUAL

Travel in CRAB mode

This function is used to adjust extended track during Machine travel.

Use potentiometer (2) to adjust travel speed, and use travel controls (1) to adjust its direction.

Press pushbuttons (5) and (6) on travel controls (1) to control the Machine in CRAB mode, and at the same you may turn the Machine.


Swivel travel controls (1) from (0) and the Machine will start moving.

Turning ON:Press button (5) to deflect the front drum to the right and press button (6) to deflect to the left, the indicator lamp on cluster (26) will light up to signal this function.

Max deflection of the front drum to both sides is 180 mm.

Turning OFF:Press switch (4) to cancel CRAB mode of front drum.

Indicator lamp on cluster (26) will go OFF to signal CRAB mode has been reset.

NoteIf the Machine is equipped with cutter and final compactor, then pushbuttons (5) and (6) on travel control (1) on the same side where it has been mounted, are used to control it.

Then pushbuttons (5) and (6) on the second travel control (1)) are used to control the Machine in CRAB mode.

Take special care when Machine travels in CRAB mode near constructed facilities so to avoid their dam-age due to any collision (hitting)! If necessary, fold the external mirrors!

68 AV 80 X4

400133

25

13

0

1

2

15

2

1 7 7

14

1

16

0 N

1


69AV 80 X4

OPERATION MANUAL

2.7.3. Machine travel and reversation incl. vibrations

Adjust max engine rpm via accelerator control (13), and adjust travel speed via speed potentiometer (2).

Use selector switch of the vibrating drum (14) to choose vibration (front / both / rear), and use vibration amplitude selector switch (15) to choose high or low amplitude.

Vibration manual switching ON/OFF mode (MAN):Use switch (16) to turn ON/OFF this function.

Press button (7) on travel control (1) to switch ON the vibration.

Indicator lamp on cluster (25) lighted up will signal this function.

Press button (7) on travel control (1) again to switch OFF vibration.

NoteMAN mode enables to switch ON vibration on stationary Machine, the travel controls (1) shall be in (0) position.

You can switch OFF the vibration by shifting travel controls (1) to neutral (N) position.

Automatic vibration switching ON/OFF mode (AUT):Use switch (16) to turn ON/OFF this function.

Press button (7) on travel control (1) to switch ON vibration.

Indicator lamp lighted up on cluster (25) will signal vibration function.

Vibration will automatically switch ON at travel speed over 0,5 km x hour–1 (0,3 MPH).

Vibration will automatically switch OFF at travel speed below 0,5 km x hour–1 (0,3 MPH).

Automatic vibration function remains enabled even after travel controls (1) have been moved via position (0).

NoteVibration can be switched OFF through shifting travel controls (1) to neutral (N) position.

2.7.4. Driving with vibrations on compacted and hard materials

During Machine travel with vibration the drums may loose contact with the materials being compacted (so called vibro-stroke) due to high level of compaction of the background material or travel with vibration on hard materials. This condition will come to light in the form of increased vibration transfer into Machine frame and onto operator’s control stand. The vibro-stroke can partly be eliminated through the increased travel speed.

It is banned to work in vibro-stroke mode in the long term!In extreme cases there is Machine damage hazard or operator’s health hazard!

2.7.5. Compacting near constructed facilities

When required to compact in the vicinity of building facilities, utility lines, buried line systems and cables, then their operating com-pany shall assess the impact of vibrations generated by the Machine so to avoid their damage.

Manufacturer bears no responsibility for damage caused by operating company!

70 AV 80 X4

400134

13

0

1

2

1 1

25

7 7

12

0 N

1


71AV 80 X4

OPERATION MANUAL

2.7.6. How to stop the Machine and its engine

Press button (7) on travel control (1) to switch OFF vibration, indicator lamp on cluster (25) will go OFF.

Stop the Machine through shifting travel controls (1) to neutral (N) position.

Use accelerator control (13) to adjust idle engine speed.

Switch over the key in the ignition box (12) to “0“ position, and tilt back the ignition box lid to close it.

Do not stop hot engine instantly but keep it running idle for 3 minutes. The engine and turbocharger will get cooled down slowly and evenly!Travel controls (1) shall be always in neutral (N) position!Switch OFF the battery disconnector during Machine shutdown!

2.7.7. Safe stopping of the Machine


Deflect travel controls (1) from position (0) and the Machine will start moving.

The Machine will stop only with the travel controls (1) set to the position. Upon the Machine shutdown the travel controls (1) shall be in the parking brake position (neutral ”N“)!

72 AV 80 X4

400135

25 26

0

1

2

11

8

9

10

1 1

0 N

1


73AV 80 X4

OPERATION MANUAL

2.7.9. Machine shutdown

Shut down the Machine on flat and solid surface at a point with no potential of natural hazard (landslides, possible flooding, etc.)

Following the engine stop, before leaving the Machine, please disconnect its battery disconnector (50 ).

Clean the Machine to remove dirt (scrapers and drums).

Make overall inspection of the Machine and repair any defects that have occurred during operation.

Lock the Machine covers and its cabin.

Do NOT stop hot engine instantly, but instead let it idle for 3 minutes. The engine and turbocharger will cool down slowly and evenly!

2.7.8. Emergency stop of the Machine

Apply this in the event of failure where the engine is unable to be shut off via the key in the ignition box, or through shifting the travel controls (1) to position (0)!

How to switch ON:Press emergency brake button (8) and the Machine will brake, engine will turn OFF and the acoustic alarm will start.

On cluster (25) the indicator lamps for seat switch, parking brake, recharging will light up, and lubrication indicator lamp will start to flicker.

How to switch OFF:Turn the press button in the direction of arrows and the acoustic alarm will get turned OFF.

On cluster (25) the parking brake indicator lamp and neutral indicator lamp will remain ON.Shift travel controls (1) to neutral (N) position, the Machine can be started again in this position.Do NOT use emergency brake to stop or switch OFF the engine during normal operation of the Machine!

2.7.10. Sprinkling

It is used to sprinkle the Machine drums.

Switch ON one of two sprinkling pumps via sprinkling pumps selector switch (11).

Indicator lamp on cluster (26) will signal the function of switching ON the sprinkling pump.

Green LEDs signal water level in the tank, red LED flashes when emptied to min.

Use potentiometer for sprinkling interval (10) to adjust sprinkling intensity within the MIN / MAX range.

Use sprinkling pushbutton (9) for additional sprinkling of the drums before the Machine runs on the bitumen surface being com-pacted.

Check water level in the tank during Machine operation.We recommend to alter the pumps following 100 motohours in order to ensure their uniform wear.

74 AV 80 X4

400140

400139

400139

400246

„0“ „I“


2.7.11. How to lift and let down the engine bonnet

Stop the Machine, shut off the engine, and disconnect battery disconnector (50).

Lift the bonnetRemove control lever (39) and insert in the hand pump (51).

Turn the bonnet lifting valve clockwise till the stop, do not tight-en the valve with force.

Pump to lift the bonnet.

Once lifted, secure the bonnet with strut.

Lift the bonnet with the engine shut off and battery disconnector disconnected!Check that no persons are under hazard when letting the bonnet down!

Let down the bonnet Pump to lift the bonnet and secure with strut.

Turn anticlockwise the valve designed to lift the bonnet, the bonnet will start to descend.

Confirm safe touch-down of the bonnet.

Remove control lever (39) and put it inside Machine cabin.

75AV 80 X4

400145

400146

3

2

1

400148

400147

2.8.1. Machine towing

To provide for towing the Machine is equipped with two lugs on front frame, and with two lugs on rear frame.

2.8. Machine transport

A Machine sunk can be hauled for a short distance if the engine is running and the travel drive and steering do work. Operator on towed Machine shall steer the Machine in the direction of hauling. Unless the engine works, or a defect ex-ists within the hydraulic system, or travel pump is broken, then you must brake off the Machine and short-circuit the hy-draulic circuit. No person may stay on the Machine towed!When braked off and hydraulic circuit for the travel is short-circuited, this means that all the brakes are disabled! Before braking off secure the Machine with wooden scotch blocks against start-ing to move!Do NOT touch hot parts of the Machine, burn hazard!

How to brake off the Machine:Lift the bonnet and secure it.

Remove hose (3) away from the clip.

Disconnect hose (1) in quick-coupler (2).

Connect hose (3) into quick-coupler (2) .

Unscrew two multi-purpose relieve valves by three threads in CCW direction [hexagon 22 mm (0,866 inc)].

Multi-purpose relieve valves are located on travel hydroelectric generator. The travel hydroelectric generator is located on the LH side, in engine compartment .

Connect battery disconnector (50).

Switch over the key in ignition box to “ I“ position.

NoteIf the key remains in “I“ position for more than 15 seconds the acoustic alarm will switch ON – to warn operator the battery has been discharged.

76 AV 80 X4

400139

478320h

400111K


Turn the bonnet lifting valve to the right, up to its stop, do not tighten with force.

Insert control lever into the hand pump and start pumping until brake indicator lamp on cluster (25) goes OFF.

Now the Machine is braked off, and it will be possible to tow it away.

Due to leakage the pressure in the brakes may lower in course of towing. Check regularly the Machine brakes do not become hot in course of towing the Machine. If brake indicator lamp will go ON in course of towing, stop towing the Machine and start pumping until the in-dicator lamp goes OFF!When towing is completed, secure the Machine with scotch blocks against its driving away, and carry out the applica-tion of its brakes!

How to brake the Machine:Turn the bonnet lifting valve to the left, up to its stop, do not tighten with force.

Put the hose (1) and (3) to its original condition.

Unscrew two multi-purpose relieve valves by three threads in CW direction [hexagon 22 mm (0,866 inc)].

Start pumping to lift the bonnet, secure the strut.

Turn the bonnet lifting valve to the left, bonnet will start to de-scend.

Confirm safe touch-down of the bonnet.

Remove control lever (39) and put it back in the Machine cabin.

Do NOT start the engine while the Machine is being towed! To tow, use unbroken hauling ropes, or drawbar of sufficient loading capac-ity 1,5 times higher than the weight of towed Machine. It is forbidden to use chains to tow the Machine.Do NOT tow the Machine for a distance over 300 m (0.19 mi) long!Max admissible deflection is 30° away from forward direction of towing!Max speed limit while towing the Machine is 2 km/hour (1.2 mph)! Hauling machine must have sufficient tractive force (power), weight and brake effect!While hauling downhill, please use a rope to attach another hauling machine to the rear part of the towed Machine so to prevent its uncontrolled motion!While towing the Machine do NOT start its engine!

NoteThese are general requirements for safe towing of a damaged machine under normal conditions. Please consult with your dealer any and all different situations that may occur while tow-ing the Machine.

77AV 80 X4

OPERATION MANUAL

2.8.2. How to load the Machine

Use loading ramps or a crane to load the Machine on its trans-porting vehicle.

For loading with crane the Machine is fitted with lifting lugs.

Observe safety regulations when load-ing and unloading!Use the crane of sufficient loading capacity!Use corresponding and unbroken rig-ging of sufficient loading capacity!The Machine must be tied to the lifting lugs on the Machine!Only a trained person (slinger) may carry out the tying of the Machine!Keep off the area beneath the hanging load!

Before lifting, the Machine joint must be secured against slight turning.

How to secure the joint:Dismantle the arm (1).

Secure the arm with pivots (2) and safety pins locks (3).

(18 520 lb)


8400 kg


400142

400143

1

400144

3

2

2

3

78 AV 80 X4

92

11

2400141


2.8.3. Transporting by the road

The Machine may pass by its own axis between its workplaces.

During movement, please observe safety measures set for the workplace.

When on highway, the Machine must be transported on a transport carrier of ad-equate loading capacity!When moving onto the transport car-rier we recommend to switch ON the ANTISTALL function.The transport carrier must be braked and mechanically locked against any un-desired move by scotch blocks (2) when loading and unloading!A person guiding the Machine must communicate with driver through using communication signals required, refer to Section 2.1.6., and must stay all the time at one point beyond reach of the Machine. At the same time he/she must be within driver’s field of view (in visual contact) over the entire period of mov-ing the Machine onto a transport carrier and down from the carrier.When moving onto a transport carrier and moving down from the carrier all the persons aside from Machine operator must move away as far as not to cause hazard if the Machine falls down!While transported the Machine must be fixed to the transport carrier with tie offs (1) in rigging points!Rigging points are the front and rear rig-ging holes in drum frames.When transporting the Machine no per-sons may be present on the Machine, driver’s control stand or transport carrier!

79AV 80 X4

2.9.1. How to operate the Machine during its running-in

Do NOT load the Machine at its full capacity when putting the new Machine into operation or following its major overhaul dur-ing the first 30 hours!

2.9. Special conditions to use the Machine

2.9.2. Operating the Machine at low temperatures

Compacting during winter season depends on the content of fine particles and water in the soil being compacted. With the temperature dropping below freezing point the soil becomes more solid and harder to compact.

At the temperatures below 0 °C (32 °F) it is possible to compact only dry soils (and stony loose materials), or carry out rapid com-paction of non-frozen materials (before soil gets frozen).

Set up the Machine for operation at low temperatures:Check concentration of engine cooling liquid. •

Exchange motor oil for the one recommended for given ex- •ternal temperature range.

Use hydraulic oil of corresponding cinematic viscosity. •

Use winter diesel oil. •

Confirm battery has been recharged. •

A precondition for proper starting at low temperatures is that the battery is OK. The Machine can be used at its full capacity only after the media have been heated to their operating tem-peratures.

2.9.3. Machine operation at high temperatures and humidity

The engine power lowers with the air temperature and moisture increasing. Due to the fact that both these factors reducing the engine power, are independent on each other, it is possible to describe their impact as follows:

each 10 °C (18 °F) of temperature rise means power drop -by up to 4 % (at constant humidity)

each 10 % of RH increase means power drop by up to 2 -% (at constant temperature).

At ambient temperatures when hydraulic oil temperature is constantly round 90 °C (194 °F), we recommend to exchange oil for the one with cinematic viscosity of 100 mm2/s.

2.9.4. Machine operation at high altitudes

With the altitudes increasing the engine power drops due to lower atmospheric pressure and lower specific weight of intake air.

While in very dusty environment, please cut short the intervals of cleaning and replacing the air filter elements; and the replacement intervals of cabin dust fil-ter, and cut short the intervals of clean-ing the coolers.Recommended interval of cleaning is 1x per week.

2.9.5. Machine operation within very dusty environment

Engine power depends on the environ-ment where the Machine is operating.

80 AV 80 X4

Notes

81AV 80 X4

Notes

82 AV 80 X4

Notes

83AV 80 X4

3. MAINTENANCE MANUAL


84 AV 80 X4

85AV 80 X4

3.1. Safety and other measures for machine maintenance

3.1.1. Safety of machine maintenance

Carry out lubrication, maintenance and adjustments:By professionally trained personnel•

In line with safety instructions given in the Operation Man-•ual

According to schedule given in the Lubrication Chart follow-•ing the hours actually worked

On the machine located on flat solid surface, secured against •self-motion (scotch blocks), and this always with the engine OFF, key removed from ignition box, and the wiring cut off

On machine parts cooled out•

After having cleaned the machine, lubrication points and •maintenance locations

Using proper, undamaged tools•

Through replacement with new original parts as per the •Spare Parts Catalogue

With sufficient lighting of the entire machine in the event of •lowered visibility and at night

so the guards and safety elements are reinstalled again •upon work completion

through retightening bolted connections – with torque •specified, and through checking the connection tightness

with the operation media heated – beware of burns – use •recommended media, only

Upon completion of the adjustment or maintenance, please examine the func-tion of all safeguard equipment!

3.1.2. Fire precautions during operation media exchanges

In terms of fire hazard the flammable liquids used on the •Machine have been divided into three hazard classes:

IInd Hazard class – Diesel oil

IVth Hazard class – mineral oils, lube greases

Oil exchange point shall be located so it does not interfere •with the explosion or fire hazard area.

It shall be identified with notice boards and signs of no •smoking and no use of open flame.

Handling area shall be sized so the capture the amount to •flammable liquid equal to the capacity of biggest vessel, transport container.

It must be equipped with portable fire extinguishers.•

To handle the oil, Diesel oil, please use such vessels like met-•al barrels, canisters or sheet-metal cans.

Transport containers shall be properly closed when stored.•

Vessels shall have one opening, be stored with the opening •on top, and secured against any flowing out or dripping of their content.

Vessels shall be designated with indelible inscription indi-•cating the content and flammability class.

86 AV 80 X4

3.1. Safety and other measures for machine maintenance

3.1.3. Ecological and hygienic principles

When operating or maintaining the Machines the user shall be liable to follow the general principles of health and environment protection according to the laws, ordinances and regulations in individual territories of the Machine use.

Hygienic principles

Crude oil products, cooling system media, battery me- -dia and coating compositions incl. thinners are materi-als harmful to health. Workers coming into contact with these products during machine operation or mainte-nance shall be liable to follow the general principles of their own health protection and conform to the safety and hygienic manuals of these products’ manufacturers.

We call your attention to the following in particular:•

Eye protection and skin protection during work with the -batteries

Skin protection during work with crude oil products, -coating compositions or cooling liquids

Proper hand washing upon work completion and before -any meal; use adequate reparation cream to treat your hands

Adherence to the instructions given in this Manual -

Always store the crude oil products, cooling system media •and battery media, and coating compositions incl. organic thinners, and also the cleaners and preserving agents, in the genuine, original and properly labelled packages. Do not admit any storage of these materials in unlabelled bottles or in any other vessels with regard to the hazard of mistaken identification (faulty change).

When skin, mucosa, eyes are accidentally stained, or va-•pours inhaled, immediately apply the first aid principles. In the event of accidental use of these products get prompt medical attention.

When working with the Machine in cases where the Machine •has platform fitted, cabin windows are left opened, always use ear protectors of adequate type and version.

Ecological principles

The media of Machine’s individual sys-tems, and some of its parts after having been discarded (dismantled, media ex-changed) become waste with hazardous properties against the environment.

This category of waste products includes the following in •particular

Organic and synthetic lubricating materials, oils and fu- -els

Brake fluids -

Cooling liquids -

Battery media and the batteries themselves -

Cooling system media -

Cleaners & preserving agents -

All dismantled filters and filter elements -

All used and discarded hydraulic or fuel hoses, rubber- -metal and Machine’s other elements, made dirty due to the abovementioned products.

The given materials and parts, when scrapped, shall be handled compliant to the respective national regulations on environmental protection, and in line with the health protection regulations, as well.

87AV 80 X4

2412

400150

MAINTENANCE MANUAL

3.2.1. Engine oil

Engine oil has been specified according to the performance classification and viscosity classification.

Performance classification perAPI (AMERICAN PETROLEUM INSTITUTE)

CCMC (COMMITTEE of COMMON MARKET AUTOMOBILE CON-STRUCTORS).

ACEA (ASSOTIATION DES CONSTRUCTEURS EUROPÉENS DE AU-TOMOBILE)

Viscosity classificationAmbient temperature and type of operation at the location where the Machine is used are decisive to determine the SAE (Society of Automotive Engineers) viscosity class.

Use of admissible oils:

API CH4/SG

CCMC D5

Year round SAE 15W-40 (e.g. Cummins Premium Blue).

NoteExceeding low temperature limit will not lead to any engine damage. It may only cause problems when starting the engine.

It is appropriate to use universal multigrade oils so there shall be no need to exchange oil due to ambient air change.

To make starting easier at the temperatures below 0 °C (32 °F) the engine oil producer recommends SAE 10W-30 oil as per the diagram.

Exceeding upper temperature limit must not be of long duration due to lowered lubricating capability of oil.

3.2. Media specification

Viscosity Diagram

88 AV 80 X4

2158


3.2.2. Fuel

The following Diesel oils are used as engine fuel:

CEN EN 590

ASTM D 975-88: 1-D a 2-D

Use winter Diesel fuel at low ambient temperatures below 0 °C (32 °F).

3.2.3. Hydraulic oil

Only the quality hydraulic oils of power class under ISO 6743/ HV (corresponds to DIN 51524 Part 3 HVLP; CETOP RP 91 H) must be used for the Machine’s hydraulic system.

Standardly refill the machines with hydraulic oil of kinematic vis-cosity 68 mm2/s at the temperature of 40 °C (104 °F) ISO VG 68. This oil is the most suitable one to use in the broadest range of ambient temperatures.

At high ambient temperatures when oil temperature reaches constantly 90 °C (194 °F) we recommend to exchange oil with cinematic viscosity of 100 mm2/s - HV 100 (BP BARTRAN HV 100; ESSO UNIVIS N 100, etc.).If it is necessary to start the Machine for the period of one month or longer at am-bient temperatures below –8 °C (18 °F), please exchange oil in the hydraulic sys-tem for the oil with cinematic viscosity of 46 mm2/s – viscosity class HV 46.At the temperatures below –13 °C (9 °F), please exchange oil for the one with cin-ematic viscosity of 32 mm2/s – viscos-ity class HV 32 (e.g. BP BARTRAN HV 32, ESSO UNIVIS N 32, etc.).

Hydraulic oil synthetic typeHydraulic system is possible to be filled with synthetic oil, which is during any leakage this oil will be restless degraded via micro-organisms found in water or in soil.

Please, always consult with the producer or dealer any switching to another type of oil or blending with other types of oils.

NoteSufficient frost resistance can be achieved also through provid-ing the fuel with additive to improve its fluidity (fuel additives).

Winter fuel mixtures are of the same ignitability like petrol – follow the fire regulations!

Do NOT use other fuels (e.g. bio diesel fuel, mixed bio diesel fuel, LFO, etc.) than those diesel fuels specified above.

89AV 80 X4

0787 2152

MAINTENANCE MANUAL

3.2.4. Lube grease

Use plastic lubricant with lithium content to lubricate the Ma-chine under the following standards:

ISO 6743/9 CCEB 2

DIN 51 502 KP2K-30

NoteFor instance Mogul LA 2, Mobilplex EP-1, Retinax A, Alvania, Grease No 3, etc.

Unless necessarily required, never use higher than 50% ratio of antifreeze cool-ant in the cooling liquid.Never use the ratio over 68%!We do not recommend antifreeze agents to be mutually mixed. Mixing together various types of coolants may case loss of antifreeze characteristics.Check the portion of antifreeze coolant in cooling liquid always before winter period, using refractometer (density meter).Health hazardous nitroamines occur when mixing nitride-based antifreeze coolant with amine-based agent.

3.2.5. Coolant

Cooling liquid in the ratio of 50% water and 50% antifreeze agent (for ambient temperature of up to -37 °C [-34 °F]) will be used within the climatic zone with no temperature drops be-low 0 °C (32 °F). Cooling liquid is not used only as protection of the cooling system against frost but also to increase the boiling point. The inhibitors contained in antifreeze agent protect the parts of engine cooling system. The propylene antifreeze agent can be used as cooling system medium as well.

Use treated demineralised or distilled water to prepare the cool-ing liquid.

The following antifreeze agents can be among others:

SUNOCO - PERMANENT ANTIFREEZE

SHELL - Glycoshell AF 511 S

TEXACO - HAVOLINE Antifreeze Coolant/AFC

CASTROL - ANTIFREEZE MB

90 AV 80 X4

2260


3.2.6. Glass washer fluid

Use water (up to 0 °C temperature) and agent for motor vehicle glass washers when filling the glass washer tank.

Replace water with antifreeze agent at the temperatures below 0 °C (32 °F).

91AV 80 X4

2412

2158

0787

2152

2412

2587

2260

2567

MAINTENANCE MANUAL3.3. Media

Part Medium TypeMedium Amount

l (gal US)Brand

Engine Engine oil under Section 3.2.1. 8 (2,11)

Fuel tank Fuel under Section 3.2.2. 110 (29,05)

Hydraulic tank Hydraulic oil under Section 3.2.3. 54 (14,27)

Drum bearings, calliper bearings, king pins, sus-pensions

Lube grease under Section 3.2.4. As required

Cooling system Coolant under Section 3.2.5. 18 (4,75)

Vibration drum Engine oil under Section 3.2.1. 2x10 (2x2,64)

Baterry Distilled water As required

Glass washer tank Liquid under Section 3.2.6. 2,75 (0,72)

Sprinkling tank Water 600 (158,5)

92 AV 80 X4

3.4. Lubrication and Maintenance Chart

2025

050

020

0010

00

3.6.

1.

3.6.

2.

3.6.

3.

3.6.

4.

3.6.

5.

3.6.

6.

3.6.

7.

3.6.

8.

3.6.

9.

3.6.

10.

3.6.

11.

3.6.

12.

3.6.

13.

3.6.

14.

3.6.

15.

3.6.

16.

3.6.

17.

3.6.

18.

3.6.

19.

3.6.

20.

3.6.

21.

3.6.

22.

Mai

nten

an.

asne

eded

3 m

onts

6

mon

ts 1

yea

rda

ily

2 ye

ars

AC

TIV

ITY

EXCH

AN

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ON

, CH

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ING

, REP

LEN

ISH

MET

, AD

JUST

MEN

T

CLEA

NIN

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BRI

CAT

ION

CHAPTERTO

BE

CA

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OU

T RE

GU

LARL

Y, E

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ours

)

400151en

Engi

ne –

oil

amou

nt

Engi

ne –

coo

lant

am

ount

Engi

ne -

belt

Engi

ne –

cra

nkca

se b

reat

her

Air

�lte

r vac

uum

val

ve

Cool

ing

circ

uit –

fan

cond

ition

Fuel

tank

– fu

el a

mou

nt

Hyd

raul

ics

tank

– o

il am

ount

Sprin

klin

g ta

nk –

wat

er a

mou

nt

Ala

rm a

nd c

ontr

ol d

evic

es

Engi

ne –

oil

and

�lte

r

Engi

ne –

indu

ctio

n m

anifo

ld

Engi

ne –

coo

ling

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uit

Batt

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Air

�lte

r vac

uum

sw

itch

Sprin

klin

g �l

ter a

nd s

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kler

str

aine

rs

Mac

hine

lubr

icat

ion

Engi

ne –

fuel

�lte

r

Engi

ne –

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lant

con

cent

ratio

n

Engi

ne -

belt

Engi

ne -

exha

ust

Sile

ncin

g sy

stem

93AV 80 X4

MAINTENANCE MANUAL

*

2025

050

010

0020

00

3.6.

23.

3.6.

24.

3.6.

25.

3.6.

26.

3.6.

27.

3.6.

28.

3.6.

29.

3.6.

30.

3.6.

31.

3.6.

32.

3.6.

33.

3.6.

34.

3.6.

35.

3.6.

36.

Mai

nten

an.

asne

eded

3 m

onts

6

mon

ts1

year

daily

2 y

ears

AC

TIV

ITY

CHA

P.

400152en

Sprin

klin

g ta

nk

Engi

ne –

val

ve c

lear

ance

adj

ustm

ent

Engi

ne -

cool

ant

Dru

ms

– oi

l in

drum

vib

rato

rs a

nd d

rum

bea

rings

Hyd

raul

ics

tank

– o

il an

d �l

ter

Fuel

sys

tem

ven

ting

Engi

ne –

air

inta

ke �

lter

Engi

ne –

fuel

�lte

r wat

er tr

ap

Engi

ne ra

diat

or a

nd h

ydra

ulic

oil

cool

er

Cabi

n –

air i

ntak

e �l

ter

Sprin

klin

g ta

nk –

wat

er d

rain

bef

ore

win

ter s

easo

n

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ms

– sc

rape

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ent

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cle

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94 AV 80 X4

3.5. Lubrication Chart

ISO: 6743/9 CCEB 2, DIN 51 502 KP2K - 30

ISO: VG 68; ISO 6743/HV

API: CH4/SJ; CCMC: DHD1; ACEA: E5; SAE 15W/40

1000 hyearly

250 hquarterly

20 hdaily

2000 hevery 2 years

Legend symbol:

Exchange

Lubricate

Inspection, Replenishment

Type of �ll:

Engine oil:

Grease:

Hydraulic oil:

LUBRICATION PLAN

400153en

95AV 80 X4

478320h

400154

MAINTENANCE MANUAL3.6. Lubrication and Maintenance Operations

Carry out lubrication and maintenance in regularly repeated intervals as per the everyday data reading on the counter of hours actu-ally worked.

This Manual includes only the basic engine information, others are given in the Engine Operaion and Maintenance Manual which is part of documentation supplied with the Machine.

Follow the instructions given in the Engine Operation and Maintenance Manual!

Following the first 250 hours of new Machine operation or after the major overhaul, please carry out the operations under this Section:

3.6.24. Valve adjustment

Removed or loose bolts, plugs, threaded joints of the hydraulics, etc. shall be tightened with the torque according to the charts in Sec-tion 3.5.36 unless a different value is given with the relevant operation.

Carry out the inspection of the Machine located on flat, solid surface secured against self-motion (scotch blocks), and this always with the engine OFF, key removed from ignition box, and with the wiring dis-connected (unless otherwise required).

96 AV 80 X4

400155

1

400156

2

400157

3.6. Lubrication and Maintenance Operations

Following the 20 hours of operation or daily

3.6.1. Inspect, refill the oil amount in the engine

Pull out oil dipstick (1), wipe it.•

Put it back down to the stop and pull out again to read the •oil level.

NoteIf the engine was running, wait ca 3 minutes until oil descends into engine sump.

NoteLow division mark L shows lowest possible oil level, high di-•vision mark H (High) shows the highest level.

The amount of oil between Low and High marks is 1,5 l (1.6 •U.S. Quart).

Following the refill, please wait ca 3 minutes until oil de-•scends into the sump, then check the level.

Do NOT run the engine unless there is correct oil level in the engine.Maintain the level between the division lines stamped on the dipstick.Refill the oil of identical type as stated in Section 3.2.1.

Replenish oil through filler-neck with the filler plug removed •(2).

97AV 80 X4

1

400158

400159

MAINTENANCE MANUAL

3.6.2. Inspect, replenish the engine coolant amount

Do it before starting the engine, visual inspection of the •level.

Top up through filler neck (1).•

Keep level between ”MIN” and ”MAX” lines.•

At higher losses find out any cooling system leakage and •repair the cause.

Wait to remove the filler plug only after engine coolant temperature drops below 50 °C (120 °F). If filler plug is removed at higher temperature then the hazard of vapour scald or coolant scald will occur due to inner overpressure effect.

Do NOT use any additives to repair cooling system leaking into the engine coolant!Do NOT refill cold coolant in hot engine! Danger of engine castings damaged.Top up only with the coolant consisting of antifreeze agents of identical base un-der the Section 3.2.5.

98 AV 80 X4

400160

400161

400156A

400162


3.6.3. Inspect the engine belt

Make visual belt inspection, monitor any of its damage. •Cracks perpendicular to the belt width are not considered a damage.

3.6.4. Crankcase breather

Check crankcase breather pipe so it is not clogged due to •any deposits, fragments, chips, or in winter frozen with ice.

When longitudinal cracks occur on the belt, or belt edges are shattered, or ex-tracted parts of material, then the belt must be replaced.

When running the Machine during low temperature period or under low tem-perature conditions, make the inspec-tions in shorter intervals.

99AV 80 X4

400163

400148A

MAINTENANCE MANUAL

3.6.5. Inspect air filter vacuum valve

Clean the exit slit, press to remove any dust trapped.•

NoteAny dust trapped in the dust valve will automatically be emp-tied with the Machine running.

Do NOT operate the Machine when dust valve is damaged.If air filter vacuum valve is damaged, re-place it with new one of identical type!

3.6.6. Inspect fan condition

Inspect visually the fan. If damaged (e.g. missing parts of •material, cracks, shape changes, etc.), replace the fan.

100 AV 80 X4

400165

1

2

400166

3

478320h

400111A


3.6.7. Check fuel amount

Check the amount of fuel on LH cluster signalled by LEDs, •and in case of lack of fuel, please replenish.

Minimal amount of fuel is signalled by red LED flickering.•

Do NOT use up fully the tank. When used up fully the entire fuel system must then be deaerated, which is rather hard and demanding. Use solely a clean recommended fuel per Section 3.2.2.NEVER replenish fuel in confined space.

Fuel must NOT be spilled.

Clean tank filler cap (1) and filler neck (2).•

Unlock tank filler cap lock, turn the filler cap and remove it.•

Refill the tank up to the bottom edge of filler neck via the •strainer (3).

NoteFuel tank capacity is 110 l (29 gal US). Fuel tank will last ca 14 hours of the Machine operation.

NO smoking and no use of open flame when at work.Do NOT refill fuel while engine is running.

101AV 80 X4

400167

1

2

400148

1

2

400112A

MAINTENANCE MANUAL

3.6.8. Inspect oil amount in the hydraulic circuit tank

Lift the bonnet.•

Check oil level in oil gauge.•

Fill up oil via the filling device using quick-coupling (1), pro-•ceed as per Section 3.6.27..

Tank filler neck cap (2) has been sealed. If this seal is damaged during guarantee period, then the Machine guarantee will terminate. Conduct this filling method as emer-gency one – not recommended by manufacturer!Oil level shall always be visible in oil gauge!Refill required oil according to the Section 3.2.3..Upon higher loss of oil, find out the cause of hydraulic system leaking (leaks through hose screw joints, screwed fit-ting of hydroelectric generators or of hydraulic motors, etc.), and repair the defects.

3.6.9. Fill up sprinkling water tank

Check water amount on the RH cluster. It is signalled by •LEDs, and in case of lack of water, please refill.

Minimal amount of water is signalled by red LED flashing.•

Perform the following before engine is started.•

Before winter period, drain water from the water tank and sprinkling system!Proceed according to Section 3.6.33.

Open the cap (1) and refill with clean water via the strainer (2).

102 AV 80 X4

478320h

400111C

478320h

400111B

1

0 I II 400164

17400128

19202122


3.6.10. Inspect alarm and control devices

Turn ON the ignition key into position I.•

On the LH and RH clusters the automatic control of the light-•ing function will occur, and this through the pilot lamps go-ing on.

Then all the pilot lamps will go off on the RH cluster, and the •lamps on the LH cluster will remain on:

Indicator lamp for the zero position of travel controller -

Brake alarm indicator lamp -

Battery charge control lamp -

Engine lubrication indicator - flickers -

Start the engine•

The indicator lamps on LH cluster must go off:•

Battery charge control lamp -

Engine lubrication indicator -

NoteIf the engine is not started within 10 sec. after ignition key has bee turned ON into position I, then acoustic signal will be en-abled (to warn operator of the battery possibly discharged).

In addition, please test if the switches (19 - 22) and the com-•bined switch (17) work.

NoteWhen lights are switched ON the luminous intensity of indicator lamps (25) and (26) on clusters will lower.

103AV 80 X4

STO

P 08

400169

N

478320h

400111D

478320h

400111

MAINTENANCE MANUAL

Start moving the Machine:Indicator lamps on LH cluster shall go OFF.•

Indicator lamp for the idle (neutral) of travel controller -

Brake alarm indicator -

Use sound signal to indicate the engine start!Before engine is started, check there is no hazard of any person if engine is started!Use sound signal before Machine starts moving and wait long enough to any persons present can leave the area round the Machine (space beneath the Machine) in time!Make sure the area in front and behind the Machine is free, with no persons present within thereof!

Emergency brake push button function:Check whether emergency brake works (8).•

The engine stalling.•

Then the following indicator lamps on LH cluster remain •ON:

Seat switch indicator lamp -

Parking brake warning lamp -

Battery charging indicator -

Engine lubrication indicator - flickers -

When travel controller is shifted to neutral position (N) the •seat switch indicator lamp goes OFF, and idle indicator lamp lights up. Now you can start the engine again.

During operation, check continuously the instruments and indicator lamps.Promptly repair any failures!

104 AV 80 X4

400171

400172

400173

400170

1


Following 250 hours of operation (after 3 months)

3.6.11. How to exchange motor oil and oil filter

Prepare an appropriate vessel of ca 20 litre capacity.•

Remove drain plug (1) and let the oil flow out.•

Clean the surface round oil filter head. Remove the filter.•

Clean seating face for filter gasket.•

When draining the oil temperature shall not be over 60°C (140°F) – risk of burn.

105AV 80 X4

400174

400175

400156

2

400170A

MAINTENANCE MANUAL

Apply oil slightly across rubber gasket for the filter and screw •back, tighten properly with hand.

Do not overtighten the filter, the thread and gasket may get impaired!

Check the drain plug gasket, replace if damaged. •

Check the thread and clean seating face for gasket. •

Reinstall the plug. Torque is 50 Nm (37 ft lb).•

Use filler neck (2) to fill the engine with clean motor oil.•

106 AV 80 X4

400178

400179


Drain oil when hot – best upon operation completion. Use original filters only.Use recommended oil under Section 3.2.1, only.To not overtighten the filter, its thread and gasket may get damaged.Check the tightness.

Collect the oil drained, do not let oil soak into soil.Dispose of oil compliant to regulations.Store used filters in a separate container and handle them so these do not pollute the environment.

NoteFill up to the dipstick’s top division mark. Total sump capac-•ity is 8 l (2,1 gal US).

When oil is exchanged, start the engine and let it run at •higher idle rmp for 2 - 3 min.

Stop the engine and wait for ca 3 min until oil descends into •the crankcase, then check the proper oil level.

3.6.12. Inspect engine induction manifold

Check the pipes and clamps.•

Do not operate the Machine if pipes and clamps are damaged!

107AV 80 X4

400180

400170B

400181

400182

MAINTENANCE MANUAL

3.6.13. Inspect engine cooling circuit

Check the cooling circuit tightness. Confirm no pipes are •damaged and no clamps are missing.

Check that oil cooling gills and radiator fins are not fouled. •If fins are fouled then clean them, for instance purging the coolers with pressure air (steam or hot water) according to Section 3.6.35

108 AV 80 X4

400129

400177

1

1

400183

2

400177A


3.6.14. Inspect the battery

Stop the engine and use disconnector to disconnect the wir-•ing.

Clean the battery surface.•

Inspect the condition of poles and terminals. Clean the poles •and terminals. Apply thin layer of grease on terminals.

Open the battery cell plugs (2) to check electrolyte level to •confirm the electrolyte level reaches 5 ÷ 15 mm (0.2÷0.6 in) above the plates (electrodes) in all the cells, or to the bot-tom edge of the gauge inside the battery cells. Refill with distilled water those cells having electrolyte less than 5 mm (0.2 in) above the plates.

Measure the electrolyte density in individual cells with the •refractometer or density meter.

109AV 80 X4

MAINTENANCE MANUAL

Compare measured values with the chart.•

Density

in g/cm3 in °Be (Beume)

20 °C

68 °FTropics

20 °C

68 °FTropics

fully charged 1,28 1,23 32° 27°

semi

charged1,2 1,12 24° 16°

exhausted -

charge

immediately!

1,12 1,08 16° 11°

NoteCheck the level with glass tube.•

Unless the Machine is going to be used during winter sea-•son for a couple of months, remove the battery and store it so it is protected against any frost. Carry out inspections of the battery and its recharging before its storage and for the period it is stored.

Use rubber gloves and safety glasses when working with the battery.Protect your skin with proper clothing against being stained by electrolyte.Upon eye contact with electrolyte im-mediately flush eyes with large amounts of water for at least a couple of minutes. Get prompt medical attention. Upon ingestion of electrolyte drink max amount of milk, water or solution of cal-cined magnesia in water.Upon skin contact with electrolyte re-move contaminated clothing, includ-ing shoes, wash affected spots as soon as possible with soap water or solution of soda and water. Get prompt medical attention. Do not eat, drink, smoke, while at work!Having finished the work, please wash your hands and your face thoroughly with water and soap!Do not try whether wires are energized through contacting Machine frame.

Do not turn the battery upside down, electrolyte may pour down from the de-gassing plugs.Flush spilled electrolyte with water, and neutralize with lime.Hand over the aged battery that does not work, for its disposal.

Keep the battery dry and clean.Close the battery when checking is completed.Refill the battery with distilled water only – never with acid.Replenish distilled water just before op-erating the Machine or before battery recharging. Recharge the undercharged battery.Recharge the battery off the Machine.Open battery plugs before recharging.Never disconnect the battery with the engine running.Follow the battery manufacturer’s man-ual when working with the battery!Disconnect the battery during its repair, or when handling the wires and electric devices within the wiring circuit to avoid any short circuit.To disconnect the battery you must first disconnect (–) pole of the cable. To con-nect, first connect (+) pole.Never make direct conductive connec-tion between the battery’s both poles, short circuit will occur with the risk of battery explosion.

110 AV 80 X4

400182A

478320h

400185

400186


3.6.15. Inspect the function of air filter vacuum switch

Adjust the engine rpm to round 1500 rmp.•

Cover briefly the air filter intake hole.•

Once covered, the indicator lamp for air filter clogged shall •light up.

Unless indicator lamp goes ON, check the vacuum switch, •contacts and feeder cables.

Inspect always when cleaning the induc-tion air pre-filter!Do not use thin paper to cover it – be-ware of intake hole clogged!

111AV 80 X4

400187

400188

21

400189

400190

3

MAINTENANCE MANUAL

3.6.16. Sprinkling filter & sprinkler strainer

Close water supply through the valve.•

Remove sprinkler filter vessel (1), replace the strainer (2) and •clean it.

Remove and clean sprinkler strainers (3).•

112 AV 80 X4

400191

400192

400193


3.6.17. Machine lubrication

• Takeoffthecapsonthegreasingnipples.

• Stepbystep,putonthegreasingnippleofhigh-pressurepressandlubricatetilltheoldgreasestartspouringout.

• Reinstallthegreasingnipplecaps.

Main bearing 4x

Linear hydraulic motors for steeringPins 6x

Steering joint Upper bearings 2 x

Lower bearings 2 x

Use only the recommended lube greases, refer to Section 3.2.4.

113AV 80 X4

400194

400195

MAINTENANCE MANUAL

Linear hydraulic motors to lift off the bonnetUpper pins 2 x

Lower pins 2 x

Cabin door hinge pinspins 8 x

114 AV 80 X4

400197

400198

2

400197A

400183


3.6.18. How to replace fuel filter

Clean the fuel filter.•

Remove the filter.•

Clean the sealing face of filter holder.•

Fill new filter with clean fuel and lubricate sealing “O” ring •(2) with oil.

Screw the filter with hand until the gasket gets seated, and •then tighten by another half-turn.

Use a hand pump to add fuel into the filter.•

Inspect the filter tightness when engine is started!•

Observe fire precautions during replace-ment!Replace in ventilated rooms with no fire hazard.Do not smoke or use open flame when at work.

Use the recommended original filters, only.Make no over-tightening of filters, the thread and gasket may get damaged.

Avoid fuel leaking into soil.Store used filters in environmentally friendly manner.

3.6.19. Inspect coolant concentration

Check the concentration via refractometer.•

Inspect always before winter season. Unless concentration for -36 °C (-33 °F) has been measured, you must adjust it through adding antifreeze into the cool-ing system.Add antifreeze according to Section 3.2.5.

115AV 80 X4

400199

400161

400200

400201

MAINTENANCE MANUAL

Following 1000 hours of operation (after 1 year)

3.6.20. Inspect engine belt

Check the belt wear:Inspect visually the belt. •

If longitudinal cracks occur on the belt, or belt edges are •shattered, or parts of material are extracted, then you must replace the belt.

Belt tension:

Check the belt and take up the slack with the engine OFF!

3.6.21. Inspect the exhaust system

Check the leak tightness of exhaust manifold in the direc-•tion towards the engine.

Check the exhaust manifold leading to the exhaust muffler.•

Torque of the exhaust-header (collector) pipe - 21 Nm.•

Check the belt with the engine OFF!

Check the belt tension:Use parking brake to secure the Machine. •

Press with your thumb at the spot where belt length be-•tween pulleys is the longest, using 6 kg (13.2 lb) strength.

Max slack is 10 mm (0,39 in). •

116 AV 80 X4

400202

400204

400205

400177B


3.6.22. Inspect the silencing system

Check the condition of rubber-metal, coherence (bond •strength) between metal and rubber.

Rubber-metal for the engine 3x.

Rubber-metal for battery holder 4x.

Rubber-metal of driver’s compartment 4x.

Replace the damaged ones.Check the bolts and nuts of the following are tightened:

Rubber-metal of drums – LH side and RH side 2x 8.

117AV 80 X4

400148A

400206

400148B

MAINTENANCE MANUAL

3.6.23. Clean the water tank

Remove the tank filler neck cap.•

Open tank drain hole.•

Flush the tank with stream of water.•

Clean the strainer inside the filler neck.•

Drain water from water tank before win-ter season!Proceed in line with the Section 3.6.33.

118 AV 80 X4

400207

400208

400209

400211


Following 2000 hours of operation (every 2 years)

3.6.24. Inspect, adjust engine valve clearance

Remove the intake.•

Remove the valve cover.•

! Contact CUMMINS service dept.!

Remove the vent pipe.•

119AV 80 X4

400212

2

400213

2

400214

1

400215

MAINTENANCE MANUAL

Rotate the crankshaft pulley towards the TDC of valve No. 1 •compression (inlet valve of cylinder No. 4 opens and both valves of cylinder No. 1 close).

Align the mark on crankshaft “1.4 T” against the indicator (2). •Cylinder No.1 is in TDC at compression cycle – both valves are free.

Check the setting gauge (1).•

Adjust the clearance (1) between valve rocker arm (2) and •valve (3). Loosen the lock nut (4) and turn the adjusting screw (5).

When adjusted tighten the lock nut. The torque is 39-49 Nm •(29 - 36 ft lb).

120 AV 80 X4

400216

I E E I

1 2 3 4

I E I E

400216A


Check the other valves.•

Turn the crankshaft by 360° (by 1 rotation).•

Valve sequence of 1÷4 is from the fan pulley.Correct clearance will be adjusted if you can feel resistance when the setting gauge moves.Tighten the lock nut and check the clear-ance again.

Adjust other valves as per the Fig.•

Valve adjustment figures (hot or cold engine): •

Inlet valve (I) - 0,35 mm (0,014 in) clearance.

Exhaust valve (E) - 0,50 mm (0,020 in) clearance.

Reinstall the valve cover, air supply manifold and engine •breather pipe.

121AV 80 X4

400159

400158A

1

400170C

400181

MAINTENANCE MANUAL

3.6.25. Engine coolant exchange

How to drain cooling circuit:

Remove the cooling circuit drain plug. Let the liquid pour •down into the vessels set up. The drained amount is ca 20 l (5.2 gal U.S.).

Before you drain the coolant from the cooling circuit let the engine run for 5 minutes for the liquid temperature to reach 82°C (180°F)Do not open overpressure plug before coolant temperature drops below 50 °C (122 °F). If you open overpressure plug the liquid may splash out causing scald.

Stop the engine.Open the cooling system by removing the overpressure •plug (1) on the expansion tank.

Check whether pipes within the engine cooling system are •not damaged, clips missing. Check the radiator condition whether not damaged, not leaking, and cooling gills not fouled with impurities. Clean and repair the radiator, if re-quired.

122 AV 80 X4

400170C

400217

400218

400158B


Clean the cooling circuit:The process of cleaning the cooling circuit is divided into two parts.

First part:Install the drain plug, fill the cooling system with the mix-•ture of the following ratio: 0,5 kg (1 lb) of sodium carbonate and 23 l of water, or agents normally available on this base.

When filled, wait for ca 2-3 min until air escapes and the cir-•cuit gets filled. Max filling rate is 10 l/min [2,6 gal US/min].

Do not close the tank with overpressure plug.•

Start the engine and let it run for 5 minutes for liquid tem-•perature to reach 82°C (180°F).

Stop the engine, drain the cooling circuit and reinstall the drain plug.

Second part:Fill the cooling circuit with clean water. When filled, wait ca •2-3 min until air escapes and the circuit gets filled. Max fill-ing rate is 10 l/min [2,6 gal US/min].

Do not close the tank with overpressure plug.•


Inspect cooling circuit tightness and liq-uid level on water gauge.

Inspect cooling circuit tightness and liq-uid level on water gauge.

Stop the engine and drain the cooling circuit.•

NoteRepeat this process until clean water flows out.

123AV 80 X4

400218

400219

400158B

400159

MAINTENANCE MANUAL

Fill the cooling circuit:Install the drain plug, fill the cooling system with new cool-•ant at the ratio of min 50 % water + 50 % antifreeze.

Wear gloves to protect your hands!Wear safety glasses or face shield to pro-tect your eyes!Fill with the coolant according to the Section 3.2.5!To make the change proceed as per the manual from antifreeze producer!

Refill the coolant to max level. When filled wait ca 2-3 min •until air escapes and the circuit gets filled. Max filling rate is 10 l/min [2,6 gal US/min]. Close the expansion tank with overpressure plug.

Start the engine and wait until the tem-perature reaches 82 °C (180 °F). Check during your waiting for any leakage of cooling liquid and check the level on the indicator.


Stop the engine.•

Check the level height on water gauge. •

Confirm the coolant level on water gauge is between MIN •and MAX.

Do not open the overpressure plug be-fore coolant temperature drops below 50 °C (122 °F). If you open overpressure plug the liquid may splash out causing scald!

Hand over the used liquid for its safe dis-posal under the regulations!

124 AV 80 X4

400220

1

400221

2

4002223

1


3.6.26. How to exchange oil in the vibrators and bearings of the drums.

How to drain oil:From drum vibrators

Locate the Machine so the plug (1) is in its lowest position.•

Remove plug (1) and let oil pour down into the vessel of 15l •(4galUS) capacity.

Reinstall the plug.•

From drum bearings

Locate the Machine so the plug (2) is in its lowest position.•

Remove plug (2) and let oil pour down into the vessel of 3l •(0.8galUS) capacity.

Reinstall the plug.•

NoteExchange oil at the time when oil is hot.

Let the drained oil to cool down below 50 °C (120 °F).

Oil filling:Into vibrators and bearings of drums

Locate the Machine so the plug (1) is in its highest position.•

Remove the plug (1).•

Check the amount of oil through loosening plug (3), oil must •flow out.

Reinstall the plug (3).•

Use port (1) to refill 2 more litres of oil (0,5 galUS). •

Reinstall the plug (1).•

Avoid oil escape into ground.

125AV 80 X4

400223

400167A

400224

1

2

MAINTENANCE MANUAL

3.6.27. How to exchange hydraulic oil and filters

Carry out oil exchange before the season starts, or following a rather long shut-down of the Machine. At the same time clean the inlet strainer, as well.

Fit a hose onto the drain valve.•

Let oil pour down into the vessel set up – total amount of oil •flowing out is 54 l (14,27 gal US).

Remove the inlet pipes.•

Remove the cap (1) along with inlet strainer (2).•

Remove the inlet strainer away from the inlet pipe. Wash •the inlet strainer and purge the strainer with compressed air from inside.

Check the inlet strainer condition, in case filter element is •impaired you must replace it.

Inspect the tank’s inner space. Should there be any impuri-•ties on its bottom, clean thoroughly and flush the tank with new oil.

Reinstall the tank’s lid (1) and use new Teflon sealing strip. •

Drain oil when cooled down below 50 °C (122 °F).Observe the fire precautions!

When disconnecting the hydraulic cir-cuits blind all the ports with plugs.Collect drained oil and do not let it soak into ground.Used oil is ecologically hazardous waste – hand it over for professional disposal.

126 AV 80 X4

400225

400167B

400167C

1

478320h

400111E


Check oil temperature sensor:Remove the sensor on the hydraulic tank cube and clean the •contact.

Fill the hydraulic circuit:Fill with the filling device of the following parameters:•

Min pressure 6 MPa (870 PSI)

Filtering property 3 to 10 µm

Slip the filling device quick-coupling over the quick-cou-•pler.

Fill the hydraulic circuit until clean oil starts pouring out from •the tank via the drain valve. Collect oil in a clean vessel.

When it reads ca 15 l (4 gal US) close the drain valve.•

Top up the tank with oil its max level and disconnect the •filling device.

Spare filling via tank filler neck:

Carry out hydraulic circuit filling via the filler neck in emergency cases only!This filling method will need to reduce the next exchange interval by one half, i.e. 1000 hours or 1 year.

Tank filler neck plug has been sealed. When this seal is bro-•ken during guarantee period then the guarantee will termi-nate.

Fill the tank through its filler neck (1) with the required type •of oil up to the bottom of a strainer inside the filler neck.

Dip the sensor in water of 100°C (212°F) temperature, check •its function correctness on the LH cluster – hydraulic oil level indicator lamp will light up, refer to the Fig.

127AV 80 X4

MAINTENANCE MANUAL

When the circuit is filled, please check the hydraulic oil level indicator lamp is not ON. Start the engine and test the Machine functions at the increased RPM so to fill the circuits.Check the filter tightness, temperature sensors, inlet pipes and lids.Observe cleanliness at work. Prevent any contamination of the system with the materials that might cause damage to the major units!Follow the fire precautions!Do not open uselessly the hydraulic tank!Exchange oil and filter element always when destruction of the inner parts of the units (hydraulic motors, hydroelectric generators) occurs, or following a major repair of the hydraulic system. Clean and flush the hydraulic tank before new unit is installed. Replace filter element.Never use chemical cleaning agents to clean the tank.To clean, please use cleaners with no fi-bre let-off.Refill oil according to the Section 3.2.3.

Note

When filling through the tank filler neck a large portion of •old oil will remain in the circuit along with the impurities, and the life of hydraulic units will lower.

You may order the filling device with the Machine manufac-•turer or a dealer.

128 AV 80 X4

400226

478320h

400111G

400227


Remove the filter vessel.•

Remove the filter element. •

Clean thoroughly the filter vessel.•

Clean from the bottom the seating face of filtration block.•

Check the condition of sealing rings and paint the rings with •clean oil.

Insert new element into the filter vessel and screw on again •– tighten with 40 +10 Nm (30 +7 ft lb) torque.

Use the original filter elements accord-ing to the Spare Parts Catalogue, only.

Used filter elements are ecologically haz-ardous waste – hand them over for pro-fessional disposal.

How to replace pressure filter element

Replace always during:oil exchange•

pressure filter indicator lamp goes •on when oil operating temperature reaches 50 - 60 °C (122 - 140 °F).

129AV 80 X4

400197A

MAINTENANCE MANUAL

Maintenance as required

3.6.28. Fuel system breathing

Deaerate the fuel system before the first start upon:filter replacement•

long term shutdown of the Machine•

fuel drawn off•

Low-pressure piping blow-off and filter deaeration:Use the pump on fuel filter head to blow off the low-pressure piping.

Avoid fuel escape into soil!

Follow safety regulations!No smoking or use of open flame while at work on fuel system!

130 AV 80 X4

478320h

400111H

400229

1


3.6.29. How to replace air filter elements

The proper maintenance of air filter and of the entire inlet piping, the rubber parts in particular, will ensure maximal protection of the engine against dust effects, and prolong the life of the element and its efficiency.

The inherent sign of fouled filter is the exhaust pipe that smokes, higher fuel consumption, output loss and engine temperature in-creased.

Principles of correct filter element replacement:Slowly pull out the clogged element as carefully as possible.•

Always clean the inner bodies of the cleaner in a way to avoid dust penetrating inside the engine feed piping.•

Clean the seating faces for gasket in the cleaner body.•

Examine the dust traces in the element removed, any traces would be an indication of its leakage in the filter body.•

Press the gasket on the new element, whether it is flexible.•

Make sure the gasket is seated properly.•

How to replace air filter element:The air filter comprises the main element and safety ele-•ment.

Replace the main element always when signalled by indica-•tor lamp for air filter fouled.

Replace the safety element always following the three re-•placements of the main element.

Confirm the fixing and integrity of the air filter and intake •piping.

Saturation of the air filter element will be signalled by the •indicator lamp for air filter fouled.

When the indicator lamp goes on you must replace the main •filter element.

Remove filter cap (1) and replace the main filter element (2) •from the filter shell.

NEVER use damaged elements!Do NOT use other elements than those required!Do NOT remove the elements just for checking purposes!Do NOT left the filter opened longer than necessarily required!NEVER operate the Machine with filter body damaged!

131AV 80 X4

400230

2

400231

3

400232

400163

MAINTENANCE MANUAL

Replace the safety element (3) from the filter shell and check •it.

Replace the safety element always following three replace-•ments of the main element.

When safety element is damaged, please replace it with the new one of identical type as per identification!

Replace instantly a damaged vacuum valve!

Clean filter’s inner space in such a way to avoid dust penetra-•tion into the inner feed piping to the engine.

Take off the air filter vacuum valve, clean it and reinstall.•

NEVER use compressed air to clean the inner space.

132 AV 80 X4

400197B

400233

1

400112B


3.5.30. How to clean water separator of fuel filter

Water trap indicator lamp is ON.•

Loosen the drain valve (1). •

Let the deposits flow out and screw it.•

Follow the fire precautions.No smoking allowed at work on fuel system.

Collect escaped fuel in the vessel set up.

133AV 80 X4

400182

400148A

400234

1

MAINTENANCE MANUAL

3.6.31. Clean the engine radiators and hydraulic oil coolers

Due to various working conditions no regular cleaning interval can be set. •

In case of work in very dusty environment, perform daily cleaning. Cooler fouling will show in a reduced cooling performance and •increased temperatures of engine coolant and of hydraulic oil.

Remove the engine air intake cover.•

Clean with compressed air or pressure water (steam). Clean •in the direction from the fan side.

Do NOT clean the radiator with too high pressure so to avoid its damage. When radiator is contaminated with crude oil products, use a cleaner and proceed according to the manufacturer’s manual! Find out a cause of contamination!

Clean the Machine at a workplace equipped with cleaner collection system to prevent soil contamination and water resource contamination!NEVER use forbidden cleaners!

3.6.32. How to clean cab ventilation filter

Remove the cover grill (1).•

Remove the filter element.•

Beat out the element carefully and wash in a detergent solu-•tion. If filter element will become damaged or unable to be made rid of the impurities, please replace it with new one.

Clean regularly 1 x per month. Should it be you work in a very dusty environment then the cleaning intervals should be cut short.

134 AV 80 X4

400206

400188

21

400187

400187A


3.6.33. Drain water from sprinkling circuit before winter season

Before winter season it will be necessary to drain water from •the sprinkling circuit with regard to any potential damage to individual parts because of frost.

How to drain water from the sprinkling circuit:Remove sprinkling water tank drain plug. Store the drain •plug at a safe place.

Tank’s full capacity is 600 l.•

Remove and clean the vessel (1) incl. sprinkling filter (2). •Store the vessel complete with filter at a safe place.

Keep the valve for water supply from the tank opened. •

Detach the water discharge hose from the pump.•

135AV 80 X4

400189

MAINTENANCE MANUAL

Detach at least one sprinkler from each pipe on the front •and rear sides of the Machine. Store the sprinklers at a safe place.

Switch ON the sprinkling pumps for 20 sec. so these become •drained.

This procedure will guarantee you max drainage of the •sprinkling circuit.

when all the abovementioned operations are completed, •please proceed in reverse steps, clean thoroughly the indi-vidual parts, first.

By draining the water from the sprin-kling circuit in time you will avoid any potential damage that the manufacturer shall bear no responsibility for!

136 AV 80 X4

400235

1

4002363

4

2

4002373

5 6


3.6.34. Adjust the scrapers

The Machine is fitted with four hinged (tilting) scrapers.•

Position the scrapers:In position (1) the scraper is set in transport position.•

In position (2) the scraper is set in working position.•

When in working position, the scraper blade (3) is pressed •against the drum body (4) by means of gas struts (4).

Replace the blade:When the blade becomes excessively worn, please lift off •the scraper, remove the bolts (5) and take off the blade (3) along with the strip (6).

Proceed in reverse steps to reinstall a new blade.•

At the same time always check the proper function of the •gas struts (4).

Only when the gas struts work properly and the worn scraper blades are replaced in time, this will provide you with perfect drum cleaning!

137AV 80 X4

MAINTENANCE MANUAL

3.6.35. Machine cleaning

When the work is completed clean the Machine to get rid of •major impurities.

Carry out overall cleaning on regular basis, at least once per •week. Total cleaning must be done daily if working on cohe-sive soils, cement or lime stabilizations.

Disconnect the disconnector.Carry out the work with the engine stopped. NEVER use aggressive or easily ignitable cleaners (e.g. petrol or easily or flash fuels).

Before pressure cleaning with water or steam, please blind all the ports into which a cleaner might penetrate (e.g. engine inlet port). With the Machine cleaned remove these blinds.Do NOT expose electric parts or insula-tion material to direct water or steam streams. Always cover these materials (alternator’s inner space, etc.).

Clean the Machine at a workplace equipped with cleaner collection sys-tem so to avoid soil or water recourse contaminations!NEVER use banned cleaners!

3.6.36. Check the tightening of bolted connections

Confirm regularly that no loosening of bolted connections •has occurred.

Use the torque spanners to do the tightening.•

TIGHTENING MOMENT

For the screws 8,8 (8G)

For the screws 10,9 (10K)

Worm Nm lb-ft Nm lb-ft

M6 10 7,4 14 10,3

M8 24 25,0 34 25,0

M8x1 19 14,0 27 19,9

M10 48 35,4 67 49,4

M10x1,25 38 28,0 54 39,8

M12 83 61,2 117 86,2

M12x1,25 66 48,7 94 69,3

M14 132 97,3 185 136,4

M14x1,5 106 78,2 148 109,1

M16 200 147,5 285 210,2

M16x1,5 160 118,0 228 168,1

M18 275 202,8 390 287,6

M18x1,5 220 162,2 312 230,1

M20 390 287,6 550 405,6

M20x1,5 312 230,1 440 324,5

M22 530 390,9 745 549,4

M22x1,5 425 313,4 590 435,1

M24 675 497,8 950 700,6

M24x2 540 398,2 760 560,5

M27 995 733,8 1400 1032,5

M27x2 795 586,3 1120 826,0

M30 1350 995,7 1900 1401,3

M30x2 1080 796,5 1520 1121,0

The figures given in the chart are torques at dry thread (with coefficient of friction = 0,14). These figures do not apply to a lu-bricated thread.

138 AV 80 X4


Chart showing the torques for cap nuts with sealing “O” ring – hoses

Tightening moments for the sliding nuts with the tightening circle „O“ - hoses

Nm lb ft

Size spanner Worm Hose Nominal Min Max Nominal Min Max

14 12x1,5 6 20 15 25 15 11 18

17 14x1,5 8 38 30 45 28 22 33

19 16x1,58

45 38 52 33 28 3810

22 18x1,510

51 43 58 38 32 4312

24 20x1,5 12 58 50 65 43 37 48

27 22x1,514

74 60 88 55 44 6515

30 24x1,5 16 74 60 88 55 44 65

32 26x1,5 18 105 85 125 77 63 92

36 30x220

135 115 155 100 85 11422

4136x2

25166 140 192 122 103 142

46 28

50 42x2 30 240 210 270 177 155 199

50

45x2 35 290 255 325 214 188 240

52x238

330 280 380 243 207 28042

139AV 80 X4

400239 400240

MAINTENANCE MANUAL

Chart showing the torques for necks with sealing edge, or with flat gasket

Tightening moments for the plugs

G -M Nm lb ft

G 1/8 15 11

G 1/4 33 24

G 3/8 70 52

G 1/2 90 66

G 3/4 150 111

G 1 220 162

G 11/4 600 443

G 11/2 800 590

10 x 1 13 10

12 x 1,5 30 22

14 x 1,5 40 30

16 x 1,5 60 44

18 x 1,5 70 52

20 x 1,5 90 66

22 x 1,5 100 74

26 x1,5 120 89

27 x 1,5 150 111

33 x 1,5 250 184

42 x 1,5 400 295

48 x 1,5 500 369

Tightening moments for the necks

G -M Nm lb ft

G 1/8 25 18

G 1/4 40 30

G 3/8 95 70

G 1/2 130 96

G 3/4 250 184

G 1 400 295

G 11/4 600 443

G 11/2 800 590

10 x 1 25 18

12 x 1,5 30 22

14 x 1,5 50 37

16 x 1,5 60 44

18 x 1,5 60 44

20 x 1,5 140 103

22 x 1,5 140 103

26 x1,5 220 162

27 x 1,5 250 184

33 x 1,5 400 295

42 x 1,5 600 443

48 x 1,5 800 590

Chart showing the torques for plugs with flat gasket

140 AV 80 X4

In most cases the defects are due to operating the Machine improperly. Therefore during any failure read thoroughly once more the instructions given in the Machine and Engine Operation and Maintenance Manual. Unless you will be able to specify the cause of a defect, please contact authorized dealer’s or manufacturer’s Help Desk (service assistance).

3.7. Defects

The troubleshooting of hydraulics and wiring requires expertise in the field of hydraulics and wiring, so we strongly recommend to hand over the troubleshooting process to the Help Desk of an authorized dealer or manufacturer.

141AV 80 X4

MAINTENANCE MANUAL

142 AV 80 X4

3.8. Attachments

A1 Clicker (course light interrupter)

A2 LH cluster

A3 RH cluster

A4 Travel electronics

A5 Travel controller

B1 Fuel level float

B3 Pressure sensor in water tank

B4 Engine RPM sensor

B5 Drum speed sensor

C1 Interference filter

E1,2 Front contour lights

E3,4 Rear lights

E5,6 Front headlamps

E7,8 Rear headlamps

E9,10 Left traffic-indicator lights

E11,12 Right traffic-indicator lights

E13,14 Auxiliary headlamps front (op-tional)

E15,16 Auxiliary headlamps rear (op-tional)

E17 Hazard beacon (optional)

E18,19 Brake (stop) lights

E20 Cabin lighting

F1-13 Cut-out fuses

G1 Battery

G2 Alternator

H1 Dipped light indicator lamp

H2 Distance light indicator lamp

H3 Loud horn

H4 Acoustic warning indicator

H5 Backing horn (optional)

K1 Contactor

K2-19 Auxiliary relay

M1 Engine starter

M2 Sprinkling motor

M3 Sprinkling motor

M4 Front wiper

M5 LH rear wiper

M6 RH rear wiper

M7 Windscreen washer

M8 Rearscreen washer

M9,10,11 Fans

Q1 Battery disconnector

R1 Sprinkling interval potentiom-eter

R2 Speed potentiometer

R3 Resistors

S1 Ignition box

S2 Combined switch

S2.1 Switch for contour lights and headlights

S2.2 Distance / dipped lights switch

S2.3 Light horn switch

S2.4 Loud horn pushbutton

S2.5 Traffic-indicator lights switch

S3 Rear headlamp switch

S4 Warning lights switch

S5 Auxiliary lights switch (optional)

S6 Hazard beacon switch (optional)

S7 Brake pressure switch

S8 Switch for hydraulics filter fouled

S9 Switch for air filter fouled

S10 Engine lubrication pressure switch

S11 Engine overheating switch

S12 Hydraulic oil overheating switch

S13 Float – water in fuel filter

S14 Backing horn switch

S15 Neutral switch

S16 Emergency brake pushbutton

S18 Constant speed or engine over-load switch

S19 Vibration automatics switch

S20 Smooth start or smooth stop pushbutton

S21 Seat switch

S22 Vibration pushbutton (red) on LH travel lever

S23 Vibration pushbutton (red) on RH travel lever

S24 Sprinkling pushbutton

S25 Sprinkling pumps switch

S26 Vibration amplitude switch

S27 Front / both / rear vibration selector switch

S28 LH (yellow) pushbutton on LH travel lever – CRAB left

S29 RH (yellow) pushbutton on LH travel lever – CRAB right

S30 LH (yellow) pushbutton on RH travel lever – CRAB left or edge cutter upward

S31 RH (yellow) pushbutton on RH travel lever – CRAB right or edge cutter downward

S32 Front wiper switch

S33 Rear wiper switch

S34 Washer double-pushbutton

S35 Fan switch

S36 Air conditioner switch (optional)

S38 Float in hydraulic oil tank

S39 CRAB resetting pushbutton

S40,41 CRAB position switches

S42 Hydraulics temperature switch

S44 Air conditioner overpressure fuse (optional)

V1-14 LED

X1 Mounting socket

X2 Diagnostics socket

X3-4 Connection terminals

X5-63 Interface connectors

Y1 Engine stop solenoid

Y3 Brake valve

Y4 Back drive valve

Y5 Rearward drive valve

Y8 Vibration low amplitude valve

Y9 Vibration high amplitude valve

Y10 Front drum vibration valve

Y11 Rear drum vibration valve

Y12 CRAB left valve

Y13 CRAB right valve

Y14 Relief valve

Y15 Edge cutter upward valve (op-tional)

Y16 Edge cutter downward valve (optional)

Y17 Air conditioner compressor clutch magnet (optional)

AV 80 X4 Wiring Diagram

Legend:

143AV 80 X4

MAINTENANCE MANUAL

S42

V14

G2

S13

X2

S38

K17

R3

V11

Y4

Y5

K4

F9

K3

H2 H1

K2

E5

E6

S2.2

S2.1

S2.3S2.4

S2.

S2

S18

B3

Y1

Y3

K10

X1

H3C1

S20

S21

K5

S23

S22

K9

S12

A3A2

S11

S9

S8

H4

B1

S7

F4

S10

S14

K7

S15

E19

E18

K8H5

E12

M

M1

K6

A4

E7

E8

E1

E2

E3

E4

E9

E10

E11

E13

E14

E15

E16

E17

F2 S1

F1

S3

F3

S4

S5

S6

F5

Q1

K1

G1

A1

S16

S19

B5

A BC

D EF

G H I J

X5:6

X5:35

X5:60

G

BLIG

11X5:21

X5:44

X5:45

X5:43

X5:41

X5:40

X5:39

X5:38

X5:37

X5:28

X5:24

X5:20

X5:19

X5:18

X5:17

X5:16

X5:15

X5:14

X5:13

X5:12

X5:11

X5:10

X5:9

X5:8

X5:7

X5:36

X5:5

X5:27

X5:26

X5:4

X5:3X5:2

X5:32

X5:25

23

95

X11:2

X7:3

X7:1

X7:7

X7:6

X7:5

7

3

1

4

2

X11:1X16:8

X16:7

X30

X55:2

X52

X54 X56:2

X51

X53

X55:1

X56:1

X49:6

X49:2

75 R

X32:1X32:2

X17:1

X15:1

X17:2

X15:2

X31

X10

X10X9

5

1

3

256a56b

56b

31

3156a

X14:1

X7:8

X6:6

X6:5

X6:4

X7:9

X7:10

X7:4

35

12

X26:3

H

B

OM

MC

C

Z

S

Y

5

1 5

7

19

7

5

21

X11:5

X13:2X11:4

X11:3 X14:2

X13:1

X12:5

X12:6

X12:4

X12:1X12:3

X12:2

X29:1

X28:3

X27:1

X27:3

X29:3

X28:4

X26:4

X29:2

X27:2

X28:2

X28:1

X26:2

X26:1

2 1

34

20

21

13

X3

9

9

18

1 5

6

14

5

12

3

19

12

12V

18

25

4

1

3

5

3

2

17

41

10

3

6

12

2

5

13

20

10

12

17

16

15P

13P

14

1

8

18

19

11

2 20

P

5A

P

MH

C

FePNP

35

12

CH

M

FePNP

35

12

7

8

6

40

28,42

3050

31

53

12

4

15A

15/5430

50

20A

1

9

5

10

15(30)A

3

82

10

6

51

1

9

5

10

1

9

5

10

10A

100Ah12V

CL

31

12

51

X60

X61

X62:2X62:15

X63:1X63:2

X62:9

X62:7

X62:4

X62:5

X62:6

X62:1

X62:8

4(C)1(H)

3(M)

X9

5

2 1

3

X62:3

02

1

Front contour lights

Rear lights

Front headlamps

Auxiliary headlamps front

Hazard beacon

Loud horn

Backing horn

Left front tra�c-indicator light

Right front tra�c-indicator light

Left rear tra�c-indicator light

Right rear tra�c-indicator light

Rear headlamps

Auxiliary headlamps rear

Brake (stop) lights

Brake Hydraulic �lterAir �lter

Engine overheatingFuel gauge

Hydraulic oil overheating

Float – water in fuel �lter

Water tank level

Brake

Travel forward

Travel backward

Hydraulic oil level

Brake

Hydraulic �lter

Air �lter

Fuel gauge

Hydraulic oil overheating

Water tank level

Engine stop

Travel forward

Travel backward

Drum speed

Engine stop

Konstant speed

Neutral

CrabEngine overload

Neutral

RS2323 TxD

RS2323 RxD

Watering

Vibration

Vibration

Instrument illumination

Instrument illumination

Air condition

Tra�c-indicator lights

Seat

Ground

Warning

Supply +12V

Charging+ motohours

Konstant speed

Ground

Warning

Supply +12V

Automat. vibration

Brake

Seat

Warning lights

Smooth start - smooth stop

Engine overload

RS2323 Grd

Engine stop

Engine lubrication

Drum speed sensor

Engine overheating

Engine lubrication

Water in fuel

107585_1cs

Hydraulic oil level

Tra�c-indicator lights



144 AV 80 X4

3.8. Attachments

A1 Clicker (course light interrupter)

A2 LH cluster

A3 RH cluster

A4 Travel electronics

A5 Travel controller

B1 Fuel level float

B3 Pressure sensor in water tank

B4 Engine RPM sensor

B5 Drum speed sensor

C1 Interference filter

E1,2 Front contour lights

E3,4 Rear lights

E5,6 Front headlamps

E7,8 Rear headlamps

E9,10 Left traffic-indicator lights

E11,12 Right traffic-indicator lights

E13,14 Auxiliary headlamps front (op-tional)

E15,16 Auxiliary headlamps rear (op-tional)

E17 Hazard beacon (optional)

E18,19 Brake (stop) lights

E20 Cabin lighting

F1-13 Cut-out fuses

G1 Battery

G2 Alternator

H1 Dipped light indicator lamp

H2 Distance light indicator lamp

H3 Loud horn

H4 Acoustic warning indicator

H5 Backing horn (optional)

K1 Contactor

K2-19 Auxiliary relay

M1 Engine starter

M2 Sprinkling motor

M3 Sprinkling motor

M4 Front wiper

M5 LH rear wiper

M6 RH rear wiper

M7 Windscreen washer

M8 Rearscreen washer

M9,10,11 Fans

Q1 Battery disconnector

R1 Sprinkling interval potentiom-eter

R2 Speed potentiometer

R3 Resistors

S1 Ignition box

S2 Combined switch

S2.1 Switch for contour lights and headlights

S2.2 Distance / dipped lights switch

S2.3 Light horn switch

S2.4 Loud horn pushbutton

S2.5 Traffic-indicator lights switch

S3 Rear headlamp switch

S4 Warning lights switch

S5 Auxiliary lights switch (optional)

S6 Hazard beacon switch (optional)

S7 Brake pressure switch

S8 Switch for hydraulics filter fouled

S9 Switch for air filter fouled

S10 Engine lubrication pressure switch

S11 Engine overheating switch

S12 Hydraulic oil overheating switch

S13 Float – water in fuel filter

S14 Backing horn switch

S15 Neutral switch

S16 Emergency brake pushbutton

S18 Constant speed or engine over-load switch

S19 Vibration automatics switch

S20 Smooth start or smooth stop pushbutton

S21 Seat switch

S22 Vibration pushbutton (red) on LH travel lever

S23 Vibration pushbutton (red) on RH travel lever

S24 Sprinkling pushbutton

S25 Sprinkling pumps switch

S26 Vibration amplitude switch

S27 Front / both / rear vibration selector switch

S28 LH (yellow) pushbutton on LH travel lever – CRAB left

S29 RH (yellow) pushbutton on LH travel lever – CRAB right

S30 LH (yellow) pushbutton on RH travel lever – CRAB left or edge cutter upward

S31 RH (yellow) pushbutton on RH travel lever – CRAB right or edge cutter downward

S32 Front wiper switch

S33 Rear wiper switch

S34 Washer double-pushbutton

S35 Fan switch

S36 Air conditioner switch (optional)

S38 Float in hydraulic oil tank

S39 CRAB resetting pushbutton

S40,41 CRAB position switches

S42 Hydraulics temperature switch

S44 Air conditioner overpressure fuse (optional)

V1-14 LED

X1 Mounting socket

X2 Diagnostics socket

X3-4 Connection terminals

X5-63 Interface connectors

Y1 Engine stop solenoid

Y3 Brake valve

Y4 Back drive valve

Y5 Rearward drive valve

Y8 Vibration low amplitude valve

Y9 Vibration high amplitude valve

Y10 Front drum vibration valve

Y11 Rear drum vibration valve

Y12 CRAB left valve

Y13 CRAB right valve

Y14 Relief valve

Y15 Edge cutter upward valve (op-tional)

Y16 Edge cutter downward valve (optional)

Y17 Air conditioner compressor clutch magnet (optional)

AV 80 X4 Wiring Diagram

Legend:

145AV 80 X4

MAINTENANCE MANUAL

X5:23

X5:22

X5:59

X5:58

X5:57

X5:56

X5:55

X5:52

X5:53

X5:54

X5:51

X5:50

X5:49

X5:48

X5:47

X5:33

X5:31

X11:13

X12:9X14:9

X12:7X14:7X14:8

X14:10

X12:16

X12:15

X12:14

X12:13

X12:12

5231

5231

X12:10

X12:8

B3B4

A4 A3

B3B4

A4 A3

C4 C3

D3D4

X49:1

X50

X49:5

X49:3X6:3

X6:1

X6:7

X35:2

X35:1

X34:1

X34:2

X19:1

X19:2

X6:2

1 2

5 3

X11:11X16:5X11:12 X16:6

X12:11

X22:5

X22:4

X22:3

X22:2

X22:1

X21:2

X21:1

X20:1

X20:2

X18:1

X18:2

X17:3

X15:3

1

57

30A

1 5

5

1 2

3

5

1 2

3

15A

7.5A

MM

1 5

X52 X6:9

X56:5

X56:4

X57:1

X59:3X58:3

X59:2

X58:2

X59:1

X58:1

X56:6

X17:2

X15:2

35

12

X32:3

10A

5

1 2

3

1

9

5

10

1

23

35

12

M1

2

3

5A

5 3

1

15A

X32:5

X32:2

X32:4

X32:1

7

3

5

1

MM

15A

1

2

3

X48:1 X48:2

X48:3

2

1

6

5

X4

P

X6:8

3(M)

1(H)2(B)

FePNP

FePNP

3(M)

1(H)4(C)

X5:30

X5:29

29 (12V)

15

X5:46

X5:42X33:1X33:25 1

6

X16:3

X16:4

X14:5

X11:10

X14:4X11:9

X11:8 X14:3

X11:7 X16:2

X16:1X11:6

(5V)

(12V)

5V

16

32

141

31

34

27

26

1K

1K 100R100R

100R 100R

MM

K18

K19

V13V12

S27

S26

Y11

Y10

Y8

Y9

E20

K13

S30

S31

S28

S29

S25

V1V2

F15

V8 V7V6 V5

Y14

S24

Y15

Y16

K12

K11

F6

F7

M3

Y12

Y13

M2

F8

S34

K14

F14

K16

S36M10

K15

M9

F13S35

V10

V9

F12

S32M4

M7

F11

M11

S39

S44Y17

S40

S41

B4A5

R2

R1

A B

C

D EF

G H I J

Reserve

If the edge cutter is instaled to left hand side of the roller change over the plug X18 to socket X19. The buttons S28, S29 on the left control lever are used to lifting cutter.

If the edge cutter is instaled to right hand side of the roller change over the plug X20 in socket X21. The buttons S30, S31 on the left control lever are used to lifting cutter.

Sprinkling 1

Sprinkling 2

Vibration - low amplitude Vibration - high amplitude

Front drum vibration Rear drum vibration

Crabing leftCrabing right

Edge cutter upward Edge cutter downward

Cabin lighting

Front wiper

Windscreen washer

Fan 1

Air conditioner

CRAB position switch - left

CRAB position switch - right

Relief valve

Fan 2

Fan 3

Engine speed sensor

Radio

Sprinkling

Engine speed

Vibration Sprinkling

Travel

Speed

107585_2en

146 AV 80 X4

3.8. Attachments

AV 80 X4 Hydraulic Diagram

Legend:

1. Travel pump.

2. Vibration pump

3. Steering and cooling pump

5. Vibration and purging block

6. Travel hydraulic motor

7. Travel hydraulic motor

8. Vibration hydraulic motor

9. Cooling hydraulic motor

10. Steering hydraulic motor

11. Crab hydraulic motor

12. Lifting hydraulic motor

13. Edge entter hydraulic motor (optional)

14. Power-assisted steering

15. RTM module

16. Filter

17. Steering block

18. Flushing (purging) block

20. Cooler combined-type

21. Hydraulic tank

22. Hand pump

23. Thermoregulator

24. Inlet strainer

25. Filler neck

26. Oil gauge

27. Check valve

28. Check valve

29. Temperature switch

30. Safety block

31. Quick-coupler filling-type

32. Quick-coupler for brake off

33. Quick-coupler for brake off

34. Quick-coupler measuring-type

147AV 80 X4

MAINTENANCE MANUAL

3233

168

52

1

34

2927

2621

2425

157

67

6

3

9 20

1714 1311 10

31

2212 30

23

18 28

2.7 ba

r

Dn10

Dn16

Dn32

Dn19Dn19 Dn19

Dn19

Dn10

Dn19

Dn19

L

R

R

L

11

X

R1

LX

1

X

L

R

i=1.0

Dn8

Dn19

Dn19

Dn13

Dn13

ot/m

in

2000

(2200

)

3 bar

750

750

P

C B

D ASS

750

750

3.5 ba

r

Dn25 100

180

Dn8

Dn10

Dn10

Dn10

Dn10

Dn13

Dn13

Dn13

Dn13

Dn13

Dn13

Dn13

Dn13

Dn16

100

T2

190

A4

Dn10

Dn10

Dn13

Dn13

Dn13

Dn13

Dn13

Dn13 Dn8

Dn13

Dn13

80/4

0-20

0

240

240

175

PT

LLD

80/4

0-20

0

AB

PT

T P

B A

20 ba

r

M

PPT3

P1XT1B1 B2 A2A1

90/4

5-12

5

13 ba

r

100

100

Dn6

14

100

Ø25 - 230

Ø25 - 230

Dn10

Dn6

Dn6

A5

Dn8

Dn8

Dn8

Dn16

A A

1 MPa

13 l/min

Dn10

P1

78

400

400

26M3M1

A B

M5M4

C1C2

TP

S1S2

L3L1

M2L2

L4

EE

L2L1

M2

C2

M5M4

BAM1M3

2233

0

330

53

C1

A B

13 l/min

1 MPa

BM

TM3

0.5 bar0.5 bar

200

C

D

3 bar

0.5 bar

2 31

P1 P2

28B

A

21

2

A1

Dn10

Dn10

Dn10

Dn10

Dn14

Dn10

400

Dn16

Dn13

3 bar

Dn10

R

P

2 31

28 B

M

A

B T

M

B M

Dn13

°C

55°C

40°C

Ø1 m

m

1411

5

°C

9.5

Ø0.5

mm

Ø0.5

mm

CRA

BIN

GED

GE

CUTT

ER

REAR

DRUM

FRON

TDR

UM

LEFT

H

YDRO

MO

TOR

OF

TRAV

EL

RIG

HT

HYD

ROM

OTO

R O

F TR

AVEL

LEFT

H

YDRO

MO

TOR

OF

TRAV

EL

RIG

HT

HYD

ROM

OTO

R O

F TR

AVEL

400252enFRONTDRUM

REARDRUM

148 AV 80 X4

Notes

149AV 80 X4

Notes

150 AV 80 X4

Notes

Ammann Schweiz AGEisenbahnstrasse 25CH-4901 Langenthal

www.ammann-group.com

Rammax Maschinenbau GmbHGutenbergstrasse 33D-72555 Metzingen

Ammann Verdichtung GmbHJosef-Dietzgen-Strasse 36D-53773 Hennef

Ammann Czech Republic a.s.Náchodská 145CZ-54901 Nové Město nad Metují

Printed in Czech Republic

av80xop tandem roller

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